FOREWORD

This manual, which is written for engineers who service the machine, describes procedures for disassembly and assembly,
inspection and maintenance, and troubleshooting, as well as maintenance reference values and an outline of the specifica-
tions. Refer to this manual during daily work to improve your services. Note that the information is subject to change without
notice due to design modifications made to the machine from time to time by the manufacturer.

Directional terms: front, rear, left, right

In this manual, the “front” refers to the end of the machine where the blade is mounted, while the “rear” refers to the other
end where the travel motor is mounted. The “right” or “left” refers to the side viewed by a person sitting in the operator’s
seat.

Machine serial number

The machine serial number is stamped on the identification plate. Be sure to include this number when sending a report or
inquiry or when ordering parts.

Control of manual
Appoint a person in charge of keeping the manuals up to date in your company and inform us of the person’s name for our
records. Any revisions or additions to this manual will be sent to the person.

Symbols used in this manual

The symbols used in this manual have the following meanings.

Indicates the machine serial number.

Means “Refer to the section quoted.”
Indicates the mass of the equipment or machine.
Means “Tighten to the torque specified here.”
Indicates the use of thread-locking compound.
Indicates the use of grease.

Manual structure
This manual consists of the following parts.
1. Safety
2. Service data
3. Function
4. Disassembly and assembly
5. Troubleshooting
6. Engine
 SAFETY 1
Safety alert symbol ...................................................... 1-2
Safety precautions ....................................................... 1-3
Cautions when working ............................................... 1-9

1-1
 1
SAFETY
SAFETY ALERT SYMBOL

SAFETY ALERT SYMBOL

This symbol represents the safety alert.
The message that follows the symbol
contains important information regard-
ing human safety.
Read and understand the message to
avoid personal injury or death.

Safety label
Safety labels are used to alert operators or other people
exposed to the risks of injury or damage. There are the fol-
lowing three types of labels.
Read the labels carefully as they are important for your
safety.

DANGER
The word “DANGER” indicates an imminently hazard-
ous situation which, if not avoided, is likely to result in
serious injury or death.

WARNING
The word “WARNING” indicates a potentially hazard-
ous situation which, if not avoided, could result in seri-
ous injury or death.

CAUTION
The word “CAUTION” indicates a potentially hazard-
ous situation which, if not avoided, may result in minor
or moderate injury.

IMPORTANT: The word “IMPORTANT” is used to alert

operators and maintenance personnel about situations
which could result in damage to the machine and its
components.

This manual is intended for trained and qualified personnel

only. Warnings or cautions described in this manual do not
necessarily cover all safety measures. It is also impossible
to cover all hazards and risks which may be associated
with the maintenance of the machine in every environment.
For maintenance work, each person must take adequate
safety precautions against possible hazards in the respec-
tive working environment.

1-2
 1
SAFETY
SAFETY PRECAUTIONS

SAFETY PRECAUTIONS Install an extinguisher and a first aid kit

Observe all safety rules

• Operation, inspection and maintenance of this machine
must be performed only by a trained and qualified per-
son.
• All rules, regulations, precautions and safety procedures
must be understood and followed when performing op-
eration, inspection and maintenance of this machine.
• Do not perform any operation, inspection or mainte-
nance of this machine when under the influence of alco-
hol, drugs, medication, fatigue or insufficient sleep.

1BAA02Z

Wear safe clothing and protective gear • Install an extinguisher to fight a fire, and learn how to use
it.
• Prepare a first aid kit and keep it at a designated place.
• Decide on the procedures to be used in case of fire or
other hazards.
• Decide on and take note of the contact(s) in case of
emergency.

Place a “Do not operate” alert sign

Serious injury or death may result if an unauthorized person
starts the engine or touches the controls during inspection
or maintenance.
1BAA01Z • Before performing maintenance, stop the engine, re-
• Do not wear loose clothing or any accessory that can move the key and store it in a safe place.
catch on the controls or the moving parts of the ma- • Prominently display a “Do not operate” alert sign on
chine. places such as the starter switch and the control lever.
• Do not wear clothing stained with oil or grease that can Place another sign outside of the machine as neces-
easily catch fire. sary.
• Wear protective gear such as helmet, safety shoes, pro-
tective goggles, respirator, gloves and earmuffs, as ap-
propriate, depending on the work involved. Especially Use the correct tools
make sure to wear protective eye-wear and mask when
working with a grinding/polishing/sanding machine,
hammer or compressed air, as metal fragments or other
objects could scatter in such an environment.
• Wear hearing protectors when operating the machine.
Loud and prolonged noise can damage or destroy your
hearing.

1BAA03Z

Do not use damaged or weakened tools or tools designed

for other purposes. Use only the correct tools for the work
involved.

1-3
 1
SAFETY
SAFETY PRECAUTIONS

Regularly replace the safety-critical parts When the canopy is tilted up

• Regularly replace fuel hoses to prevent a fire hazard. • If the canopy is raised or lowered while the engine is
Hoses wear out over time, even if they do not show any moving, the machine may accidentally start moving, re-
symptom of wear. sulting in severe injury to the maintenance personnel.
• Regardless of the replacement schedule, replace imme- Make sure that the working equipment has been low-
diately if a symptom of wear is found. ered to the ground and the engine has been turned off
before raising/lowering the canopy.
• When the canopy is tilted up, firmly secure the canopy
Explosionproof lighting with a stopper to prevent it from falling.

Keep the machine clean

1BAA04Z

To prevent an ignition or explosion, use explosion-proof

lights when inspecting fuel, oil, coolant or battery fluid.
1BAA06Z

• Clean the machine before performing maintenance and

Prohibit access by unauthorized persons try to keep it clean.
• Before washing, cover the electrical parts with vinyl to
prevent water from entering, as this could cause a short-
circuit or malfunction. Do not use water or steam to
wash the battery, sensors, connectors or the operator’s
seat area.

Stop the engine before performing maintenance

Make sure the engine is stopped before starting inspection
or maintenance. If maintenance must be performed with
the engine running, always work as a 2-person team, com-
municating with each other.
1BAA05Z • One of them must sit at the operator’s seat and stop the
Do not allow unauthorized personnel in the work area while engine whenever necessary. He/she must take care not
working. to touch the lever or pedal unless necessary.
Take particular care that no unauthorized person is present • The one who performs maintenance must make sure to
when grinding, welding or using a hammer. keep his/her body or clothing away from the moving part
of the machine.

Prepare the work area

• Select a level and firm ground on which to perform
maintenance work. Make sure that the work area is light
enough and well ventilated.
• Straighten any obstacle or dangerous object, remove
any spill of oil or grease and clean the work area.

1-4
 1
SAFETY
SAFETY PRECAUTIONS

Keep clear of the moving fan and belt When working on the machine

1BAA07Z 1BAA09Z

• Any object that can be easily caught in moving parts • To prevent slipping/falling from machine, clear the foot-
must be kept away. ing and observe the following:
• If a hand or tool becomes trapped in the fan or fan belt, a. Do not spill oil or grease on the machine.
you could lose your finger. Do not touch the fan or belt b. Keep the machine tidy and clean.
while they are moving. c. Be careful when walking around the machine.
• Never jump down from the machine. Climb up/down
the ladder (steps) holding the handrail to support your
When working under the machine weight in a three point secure stance (hand and feet).
• Wear protective gear according to the work involved.

Securing the working equipment

When replacing/repairing the bucket teeth or side cutter,
secure the relevant equipment to prevent any accidental
movement.

Secure the engine hood and guard when they are

open
Firmly secure the machine when the engine hood or guard
1BAA08Z is left open. Do not keep the hood or guard open on a
• Before performing maintenance or repairs under the windy day or if the machine is parked on a slope.
machine, set all movable equipment against the ground
or in the lowermost position.
• Place chocks under the crawler tracks to secure the Place heavy components in a stable position
machine.
• If it is unavoidably necessary to work under the raised
machine or working equipment, be sure to firmly sup-
port it by using an arm stopper, wooden block, stand
or safety brace. Never go under the raised machine or
working equipment without such protection measures.

1BAA10Z

When it is necessary to temporally place a heavy compo-

nent, such as the hoe attachment, on the ground during
removal or installation, be sure to place it in a stable posi-
tion.

1-5
 1
SAFETY
SAFETY PRECAUTIONS

Caution when filling with fuel or oil Be careful with hot and pressurized components

1BAA11Z 1BAA12Z

• Keep away from heat, sparks and flame while filling with Before performing inspection and maintenance, stop the
fuel or oil. engine and allow the machine to cool down.
• Never remove the fuel cap or try to fuel when the engine • The engine, muffler, radiator, hydraulic lines, sliding parts
is running or still hot. and many other parts of the machine are hot immediate-
• Maintain control of the fuel filler nozzle when filling the ly after the engine is stopped. Wait until it cools before
tank. making any inspection or adjustments.
• Refill with fuel or oil outdoors or in a well ventilated place, • The engine coolant, hydraulic oil and other oils are also
with the engine turned off. hot and under high pressure. Touching these liquids will
• Clean up spilled fuel or oil immediately. cause burns.
• Do not overfill the tank.
• Firmly tighten the fuel cap or oil cap. If the fuel cap is
lost, replace it only with the original manufacturer’s ap- Handling of radiator
proved cap. Use of a non-approved cap without proper
venting may result in pressurization of the tank.
• Never use fuel for cleaning.
• Use the correct grade of fuel for the operating season.

Handling of hoses
Oil leak or fuel leak can cause a fire.
• Do not twist, bend or hit the hoses.
• Never use twisted, bent or cracked pipes, tubes or hos-
es; otherwise, they may burst.
• Retighten loose connections.
1BAA13Z

Do not remove the radiator cap when the coolant is hot.

Wait until it cools down, and then remove the radiator cap
by loosening it slowly to release the internal pressure.

1-6
 1
SAFETY
SAFETY PRECAUTIONS

Be careful with oils under pressure Be careful with grease under pressure

1BAA14Z 1BAA15Z

Pressure is maintained in the hydraulic circuit long after the In the track adjuster, the grease has been injected under
engine has been shut down. high pressure. If the tension is adjusted without following
• Do not fill with, dispose of fuel/oil, or perform the in- the prescribed procedure, the grease discharge valve may
spection and maintenance until the internal pressure is fly off, resulting in injury.
completely released. • Loosen the grease discharge valve slowly.
• The hydraulic oil escaping from a small hole can be haz- • Do not put your face, arms, legs or body in front of the
ardous if contacted. It is under high enough pressure to grease discharge valve.
penetrate the skin or eyes and cause serious injury. If
leak is suspected, protect your eyes and skin by wear-
ing protective glasses and thick gloves to search for a Handling of the accumulator
leak. Also use a paperboard or plywood to keep your
skin from oil spurting. If oil penetrates the skin, it must
be surgically removed within a few hours by a doctor
familiar with this type of injury.

Release internal pressure before working on the

hydraulic system
Oil may spurt out if caps or filters are removed or pipes are
disconnected before releasing the pressure in the hydraulic
system.
• Gradually loosen the vent plug to release the internal
pressure of the hydraulic oil tank. 1BAA16Z

• Move all the control levers and pedals several times in all Be sure to handle the high-pressure nitrogen gas enclosed
directions to release the pressure from the circuit of the in the accumulator with care according to procedure. If
working equipment (for link type controls). handled incorrectly, it could explode and cause serious in-
• When removing plugs or screws, or when disconnect- jury. Strictly observe the following precautions:
ing hoses, stand to the side and loosen them slowly to • Do not disassemble.
gradually release the internal pressure before removing. • Do not allow flame near it or throw it into a fire.
• Do not drill, weld or fuse.
• Do not subject it to physical shock such as hitting, rolling
or dropping.
• Before disposing of the unit, the sealed gas must be
drained. Contact your sales or service dealer for help
with this.

Disconnect the battery

Disconnect the wiring from the both terminals (+ and -) on
the battery before working on the electrical system or doing
electric welding. Otherwise, short-circuit and explosion of
the battery can result.

1-7
 1
SAFETY
SAFETY PRECAUTIONS

Use caution when handling batteries Have a service agent repair welding cracks or
other damage
Ask a service agent to make any repairs that require weld-
ing. If the agent is unavailable, make sure the welding is
done by a qualified person in a properly equipped work-
place.

Checks after maintenance

• Gradually raise the engine speed from low idle to maxi-
mum and check that no oil or water is leaking from the
parts serviced.
• Move the controls and check that the machine is oper-
1BAA17Z ating properly.
• Batteries contain sulfuric acid which will damage eyes or
skin if contacted.
• If eye contact occurs, flush immediately with clean Disposing of wastes
water and get prompt medical attention.
• If accidentally swallowed, drink large quantities of
water or milk and call a physician immediately.
• If acid contacts skin or clothing, wash off immediately
with a lot of water.
• Wear protective glasses and gloves when working with
batteries.
• Batteries generate flammable hydrogen gas which may
explode. Keep away from flame and sparks.
• Do not use or charge the battery when the electrolyte
level is lower than the lower limit: otherwise, it could
cause an explosion.
• Be sure to stop the engine by turning off the starter 1BAA18Z

switch before inspecting or handling the battery. • Always collect oil that is drained from the machine in
• Be careful not to let metal tools (or any metal objects) containers. Improperly disposed waste oil can cause
such as a hammer or spanner come into contact with environmental harm.
the battery terminals. • Follow appropriate laws and regulations when dispos-
• When disconnecting the battery wiring, always discon- ing of harmful objects such as oil, fuel, coolant, solvent,
nect it from the earth side (-). When connecting, connect filters and batteries.
the earth side last.
• Loose battery terminals may result in sparks. Be sure to
fasten terminals tightly.
• Make sure the battery caps are tightened securely.
• Do not charge a battery or jump-start the engine if the
battery is frozen; otherwise it may explode.
Warm the frozen battery to 15°C (60°F) before use.

1-8
 1
SAFETY
CAUTIONS WHEN WORKING

CAUTIONS WHEN WORKING When removing/installing the hydraulic unit

• Make sure that the temperature of the hydraulic oil has
When disassembling or assembling dropped and is cool enough to work with.
• Clean the machine before disassembly. • To prevent the hydraulic oil from escaping under pres-
• Check the following items and record the results: sure, release the residual pressure in the piping.
a. Model, machine serial number, hour meter. • Be sure to install caps or plugs on all openings in the
b. Reason for repair, repair history. hydraulic unit to prevent dirt from getting into the unit
c. Are the filters dirty? through them.
d. The conditions of the fuel and oil. ����
�������
e. Any damage or looseness to any part? �������
• Where necessary, draw alignment indicators to avoid
assembly errors. To avoid misconnection, place indica-
tors such as reference tags on pipes.
• Clean all disassembled parts and new parts, arrange
them neatly, and place indicators as necessary.
• Be sure to replace all seals and cotter pins with new
ones.
• Keep those parts that should not come in contact with ����
water or oil away from those with oil on the surface. �������
�������
• When installing bearings, bushings and oil seals, a press
tool should be used. If a hammer is used, use a cushion- 1CAA02Z

ing material to avoid damage. • The hydraulic oil adhering to the unit is often mistaken
• Wipe all joining surfaces clean until there is no dirt or for an oil leak, so wipe off the unit thoroughly.
dust adhering to them. • Be sure that no damage is caused to the plating on the
• Wrap the thread tight with seal tape starting 1 or 2 rod in the hydraulic cylinder.
threads away from the thread end. The tape should be • Removal and installation of the hydraulic cylinder should
overlapped by about 10 mm. be done with the rod fully retracted.
• Be sure to bleed the air after installing the hydraulic cyl-
������������
�������������
inder. ( “4. Disassembly and assembly: Cylinder”)
�������� ���������� • Always bleed the air when hydraulic oil is changed or a
hydraulic device is replaced.( “4. Disassembly and
assembly: Drive system”)

��������������������������
��������������������������������
���������������������������������� 1CAA01Z

1-9
 1
SAFETY
CAUTIONS WHEN WORKING

When connecting/disconnecting the hoses or Handling of seals

pipes • Clean the grooves for O-rings and remove any burrs.
• When hydraulic hoses or pipes are connected, tighten
them once to the prescribed torque, then loosen them
slightly and retighten them to the prescribed torque.
����
a. Tighten the fittings after the installation surfaces fit ����
snugly together. ������
b. The above procedures do not apply to fittings with
seal tape.
• Use two spanners, one to tighten/loosen and the other
����
to secure the mating hose/pipe to ensure that the hose �������
is not twisted. ������

1CAA05Z

• Be careful not to twist the O-rings. If twisted, remove it

with your fingertips.
• When inserting, be careful not to damage the seal.
• Handling of the floating seal
a. After removal, wipe all oil off the O-ring and housing
of the floating seal.
b. When assembling, apply a thin coating of gear oil to
the contact surface of the housing,
c. After assembly, turn the seal two or three times to get
1CAA03Z it to fit snugly.
• After connecting the hydraulic hoses or pipes, apply the • Apply grease to the lip of the oil seal.
maximum working pressure five or six times to check for a. This is to prevent wear from occurring upon first start
leakage. up after assembly.
• If high pressure, vibration or shock is applied to a twist-
ed hose, oil leak, hose breakage or damage to the hose
fitting can result.
• Be sure that the hydraulic hoses are not contacting
sharp objects or each other. This could cause surface
flaws on the hoses, resulting in breakage.

������
�����������
��������
1CAA06Z

1CAA04Z

1-10
 SERVICE DATA 2
Dimensional drawing ................................................... 2-2
Specifications tables .................................................... 2-4
Lubricant and Fuel chart .............................................. 2-9
Performance criteria .................................................. 2-11
Tightening torque ...................................................... 2-21
Hydraulic circuit diagram ........................................... 2-25
Electric circuit diagram............................................... 2-33
Wire harness wiring diagram ...................................... 2-37

2-1
 2
SERVICE DATA
DIMENSIONAL DRAWING

DIMENSIONAL DRAWING
Machine dimensions

Unit: mm
Standard arm Middle arm Long arm
Rubber crawlers Steel crawlers Rubber crawlers Rubber crawlers
A 5470 5470 5510 5550
B 1690 1690 1690 1690
C 2515 2520 2515 2515
D 1435 1435 1435 1435
E 630 625 630 630
F 1985 1920 1985 1985
G 2500 2425 2500 2500
H 1840 1840 1840 1840
J 400 400 400 400
K 335 330 335 335
L 2170 2170 2195 2235
M 1680 1680 1705 1740
P 715 715 715 715
Q 710/705* 710/705* 710/705* 710/705*
R 1840 1840 1840 1840
S 430 430 430 430
T 4070 4070 4110 4150
U 1720 1720 1720 1720
V 80º/75º * 80º/75º * 80º/75º * 80º/75º *
W 60º 60º 60º 60º

* : Serial No. 125000295 or later

2-2
 2
SERVICE DATA
DIMENSIONAL DRAWING

Operating range

Unit: mm
Standard arm Middle arm Long arm
Rubber crawlers Rubber crawlers Rubber crawlers
A 5850 5990 6135
B 5705 5850 5995
C 3475 3625 3785
D 2725 2860 2990
E 3935 3985 4055
F 5625 5715 5800
G 3990 4085 4175
H 1595 1450 1295
J 435 435 435
K 355 355 355

2-3
 2
SERVICE DATA
SPECIFICATIONS TABLES

SPECIFICATIONS TABLES
Cab kg 4965
Operating mass
Canopy kg 4825
Net (ISO 14396) kW/min-1 29.5/2400
Rated output
Net (ISO 9249/SAEJ1349) kW/min-1 28.4/2400
Heaped capacity m3 0.141
Bucket capacity
Struck capacity m3 0.102

Performance
Standard loading mass kg 184
Slew speed min-1 9.8
1st km/h 2.8
Travel speed
2nd km/h 5.2
Maximum tractive force kN 56.1
% 58
Gradeability
degree 30
Cab kPa 28.1
Ground Pressure
Canopy kPa 27.3
Sound-power level dB(A) LWA 96
Noise Level
Sound-pressure level dB(A) LPA 77

Machine dimensions
Overall length in transport condition mm 5470
Overall width mm 1840
Overall width Track retracted mm ––
Overall working equipment Cab mm 2515
height in transept position Canopy mm 2515

Dimensions of base machine

Overall length of base machine mm 2965
Overall width of base machine mm 1840
Overall width of base machine Track retracted mm ––
Upper structure overall width mm 1690
Left mm 860
Upper structure overall width
Right mm 830
Cab overall length mm 1030
Overall height of base machine mm ––
Slew radius mm 1435
Upper structure rearmost distance from axis of rotation mm 1400
Clearance height under upper structure mm 630
Crawler base mm 1985
Crawler overall length mm 2500
Undercarriage overall width mm 1840
Undercarriage overall width Track retracted mm ––
Track gauge mm 1440
Track gauge Track retracted mm ––
Track shoe width mm 400
Ground clearance of undercarriage mm 335

2-4
 2
SERVICE DATA
SPECIFICATIONS TABLES

Engine
Model YANMAR 4TNV88
Type 4-cycle, vertical, water-cooled, in-line, 4-cylinder diesel engine
Number of cylinders -bore×stroke mm 4−88×90
Total displacement mL 2185
N·m 131.8 to 143.4
Maximum torque
min-1 1440
Specific fuel consumption (at rated output) g/kW·h 243
Fuel/air washer Centrifugal, filter paper
Fan Suction type
Cooling system type
Radiator Pressure type
Voltage V 12
Starter motor
Output kw 2.3
Voltage V 12
Generator
Output kw 0.48
Voltage V 12
Battery Capacity A·h 92
Qty. 1
Hydraulic system
Hydraulic pump drive system Engine direct coupling
Type Variable displacement type double axial piston plus double gear
Qty. 1
Hydraulic pump
Delivery L/min 58.3×2+38.9+10.8
Hydraulic pump control system All horsepower control
Main relief valve pressure setting MPa 21.0×2+19.6+3.4
Hydraulic tank pressure Pressure tank
Type Directional control valve, 10 valves in series (standard spec.)
Control valve
Operation type ––
Type Glass fiber filter type
Hydraulic oil filter Filter precision BETA10=6
Installing position Return Circuit (In Hydraulic tank)
Cooling system type Air cooling
Hydraulic oil cooler
Radiation of heat area m2
Operating equipment
Position Left side
Cab
Construction Suspension seat, adjustable
Steel enclosed cabin with all glass doors tempered glass,
Cab or canopy Construction
Steel posts canopy
Shifting operation Second travel speed switch
Travel operation Pilot operated (2 levers)
Slew operation Pilot operated
Arm operation Pilot operated
Operating lever and pedals
Bucket operation Pilot operated
Boom operation Pilot operated
Boom swing operation Mechanics, Pedal
Others Auxiliary hydraulics operating: Pilot operated and pedal
Water temperature gauge, Fuel gauge, Hour meter, Charge,
Instrument, switches Cluster gauge
Oil, Water temperature, Decel, Air cleaner, 2nd-speed pilot
Head ligh V-W 12V-55W H3-Halogen
Lighting installation
Boom light V-W 12V-55W H3-Halogen
Warning, safety device 12V,110dB(A)
Others Cab: Wiper, Heater, With defroster

2-5
 2
SERVICE DATA
SPECIFICATIONS TABLES

Slew equipment
Slew bearing Type Ball bearing
Type Variable displacement piston motor
Slew motor
Qty. 1
Reduction gears Type Epicycle reduction gear
Type Brake valve with a shockless relief
Slew brake
Qty. 1
Slew parking brake parking Type Wet friction plate type
Slew lock Type ––

Lower Machinery
Power transmission device
Variable displacement type double axial piston motor, With
Type
Travel motor counterbalance valve
Qty. 2
Reduction gears Type Epicycle reduction gear
Travel brake Type Operation delay with a counter balance valve
Parking brake Type Wet friction plate type
Undercarriage
Steel crawler with triple
Type Rubber track
grouser
Number of shoes
Qty. 74 38
Track shoe (One side)
Shoe width mm 400 400
Grouser height mm –– 14
Rug height mm 25 ––
Carrier roller (One side) Qty. 1
Roller
Track roller (One side) Qty. 5
Track adjuster Type Grease cylinder type (with cushion springs)
Track gauge extension mechanism ––

Working equipment
Hoe attachment
Heaped m3 0.141
Bucket capacity
Struck m3 0.102
Standard mm 585
Bucket width
With side cutter mm 630
Bucket mass kg 110
Boom length mm 2820
Arm length mm 1450
Bucket wrist radius mm 835
Bucket wrist angle degree 188
Left degree 78/76*
Boom swing angle
Right degree 58
Eccentric quantity of boom swing pivot mm 85

2-6
 2
SERVICE DATA
SPECIFICATIONS TABLES

Working dimensions
Maximum reach mm 5850
Maximum reach at ground reference plane mm 5710
Minimum level floor radius mm 1835
Maximum digging depth mm 3475
Reach at maximum digging depth mm 2400
Maximum vertical digging depth mm 2725
Maximum height of cutting edge mm 5625
Reach at maximum height mm 3095
Maximum dumping height mm 3990
Reach at maximum dumping height mm 2850
Minimum dumping height mm 1595
Minimum radius of equipment and attachment mm 2170
Minimum radius of equipment at maximum front offset mm 1680
Overall height at minimum radius of equipment and attachment mm 4320
Overall height of equipment at maximum front offset mm 4320
Left mm 715
Offset distance of bucket
Right mm 710/705*

Main structure
Type ––
Bucket
Number of teeth Qty. 4

Hydraulic Cylinder
Number of cylinders Qty. 1
Boom cylinder Bore mm 100
Stroke mm 690
Number of cylinders Qty. 1
Arm cylinder Bore mm 90
Stroke mm 750
Number of cylinders Qty. 1
Bucket cylinder Bore mm 80
Stroke mm 585
Number of cylinders Qty. 1
Swing cylinder Bore mm 90
Stroke mm 620/615*

Digging force
Bucket cylinder kN 37.2
Maximum digging force
Arm cylinder kN 25.9
Maximum lifting force Boom cylinder kN 26.3
Other attachment (Option) Long arm, Middle arm

* : Serial No. 125000295 or later

2-7
 2
SERVICE DATA
SPECIFICATIONS TABLES

Dozer blade
Type Straight type
Operation type Hydraulic lifting type
Number of cylinders Qty. 1
Dozer blade cylinder Bore mm 110
Stroke mm 175
Dimensions
Width mm 1840
Dozer blade dimensions
Height mm 430
Cutting angle degree 69
Distance between the front end of dozer blade and
mm 1720
the axis of rotation
Dozer blade maximum lifting mm 435
Dozer blade maximum lowering mm 355
Dozer blade approach angle degree 32.5

2-8
 2
SERVICE DATA
LUBRICANT FUEL AND CHART

LUBRICANT AND FUEL CHART

Select the appropriate fuel, lubricant and grease according to the temperature by referring to the table below.
• Regardless of the specified time, change the oil if it becomes too dirty or degraded.
• When refilling, never mix oils of different brands. If a brand is to be changed, replace the whole fuel/oil.
Type by air temperature When to change/
Part Type Capacity
-20 -10 0 10 20 30 40°C replenish

Diesel engine oil

API: CD class SAE 10W-30 Every 250 hrs after Upper limit 7.4 L
Engine oil pan
ACEA-E3, E-4 or SAE 15W-40 the first 50 hrs Lower limit 4.0 L
E-5

Takeuchi genuine
ISO VG46 Every 4000 hrs***
hydraulic oil 46
Total amount of oil:
88 L
Hydraulic oil tank
Tank capacity:
ISO VG32 52 L
Anti-wear hydrau-
ISO VG46 Every 2000 hrs***
lic oil
ISO VG68

Cooling water
(water + coolant)**
Engine cooling SAE-J814C, J1941, Mixture of 50% coolant
Every 1000 hrs 12.4 L
system J1034 or J2036 Mixture of 30% coolant
ASTM-D6210 or
D4985 (USA)
Travel reduction Gear oil Every 1000 hrs after
SAE 90 0.8 L
gear API: GL-4 the first 250 hrs*
Gear oil
Carrier roller SAE 90 –– 0.060 L
API: GL-4
Mobil oil
Track roller –– –– 0.065 L
SHC 680
Gear oil
Idler SAE 90 –– 0.070 L
API: GL-4
Slew bearing Every 50 hrs
Lithium grease
Working equip- Daily or every
EP-2 –– As required
ment 10 hrs
NLGI No.2
Levers When required

* If the ratio of traveling time to total operating time is high, replace the gear oil earlier than the specified time.
** For water, use tap water (soft). Do not use well or river water.
When the ambient temperature drops below 0°C, add coolant (antifreeze). Follow the coolant manufacturer’s instruc-
tions to determine the mixture ratio.
*** The replacement interval for hydraulic oil depends on the oil type being used. New machines are shipped from the fac-
tory with the Takeuchi genuine hydraulic oil 46. This manual describes when to replace the hydraulic oil assuming that
this Takeuchi oil 46 is used. When a conventional antiwear hydraulic oil is used, replace it every 2000 hours.

2-9
 2
SERVICE DATA
LUBRICANT FUEL AND CHART

Diesel fuel standards

Use the diesel fuel that is compliant with any of the stan-
dards below. The table below shows the standards from
the various countries.
Diesel fuel standards Region
No. 2-D, No. 1-D, ASTM D975-94 USA
EN590:96 EU
ISO 8217 DMX International standard
BS 2869-A1 (or A2) UK
JIS K2204 Grade, 2-go Japan
KSM-2610 Korea
GB252 China

Part Type Capacity

To keep the performance and service life of the engine, always
use the clean and high-quality fuel.
• To avoid freezing in cold climates, use a light oil that still
functions when the temperature is at least 12°C below the
lowest expected ambient temperature.
• Use a light oil that has a cetane number of 45 or higher.
When operating at a very low temperature or at a high alti-
tude, a higher cetane number fuel will be required.
• The sulfur content must be less than 0.5% by volume. he
recommended value, however, is less than 0.05%. The
Fuel tank Desel fuel 73 L
electronically-controlled engine with an EGR system should
use fuel containing less than 0.05% sulfur.
Fuel containing a high content of sulfur may cause sulfuric
acid corrosion inside the cylinder.
• Do not mix diesel fuel with any kerosene, used engine oil or
leftover fuel.
• Poor quality fuel can degrade the engine performance. It
also can damage the engine.
• Avoid using additives to fuel. Some fuel additives can de-
grade the engine performance.

2-10
 2
SERVICE DATA
PERFORMANCE CRITERIA

PERFORMANCE CRITERIA
Standard values table
Item Standard values Allowable value
Idling min -1
1150 ±100 ––
Engine speed
Maximum R. P. M min-1 2565 ±80 ––
Boom MPa 21.0 +1.3
-0.4 ––
Arm MPa 21.0 +1.3
-0.4 ––
Hydraulic oil pressure Dozer blade MPa 19.6 +2.0
-0 ––
Slew MPa 19.1 +2.2
-0 ––
Pilot pressure MPa 3.4 ±0.3 ––
Retracted s 2.9 ±0.5 3.7
Extended s 3.0 ±0.5 3.8
Boom cylinder
Retracted s
Extended s
Retracted s 2.4 ±0.4 3.0
Arm cylinder
Extended s 3.2 ±0.4 3.9
Retracted s 2.2 ±0.4 2.8
Bucket cylinder
Extended s 3.1 ±0.4 3.8
Cylinder speed
Retracted s 4.8 ±0.8 6.1
Extended s 4.9 ±0.8 6.2
Swing cylinder
Retracted s
Extended s
Retracted s 2.5 ±0.4 3.2
Extended s 2.7 ±0.4 3.4
Dozer blade cylinder
Retracted s
Extended s
Normal speed s 12.0 ±1.0 14.2
Slew time
Slow speed s
Overrun when slewing stops mm 120 ±50 222
Slew bearing mm 0
Natural slew drop
Swing cylinder mm 5 -50
Rubber s 13.0 ±1.5/12.9 ±1.2* 15.8
Low speed
Steel s 13.7 ±2.0 17.1
Travel speed (10m)
Rubber s 8.5 ±1.5/8.1 ±1.5* 11.2
Hight speed
Steel s 9.1 ±2.0/8.7 ±2.0* 12.4
Rubber s 34.0 ±1.5/33.7 ±1.5* 38.9
Low speed
Steel s 36.5 ±2.0/36.2 ±2.0* 42.2
Travel speed (5 rev.)
Rubber s 18.4 ±1.0/18.3 ±1.0* 22.0
Hight speed
Steel s 19.7 ±2.0/19.6 ±2.0* 24.5
Straight travel mm 125 -125
0
500
Bucket
Straight travel function Arm Straightness should be remained when
check Boom operated at the same time
Blade
Bucket cylinder speed Retracted s 5.2 ±1.0/5.0 ±1.0* 6.7

2-11
 2
SERVICE DATA
PERFORMANCE CRITERIA

Item Standard values Allowable value

Boom mm 6 -60 12
Arm mm 8 -80 16
Arm (With emergency shut-off valve) mm 4 -40 8
Natural cylinder drop Bucket mm 5 -50 10
Dozer blade mm 5 -50 10
Bucket tip mm 110 -1100
220
Bucket tip (With emergency shut-off valve) mm 80 -800
160
Backlash mm 17 ±10 34
Right operating lever mm 4 -40 ––
Left operating lever mm 4 -40 ––
Lever play
Travel mm 4 -4/5 -50*
0
––
Dozer blade mm 25 -250
––
Swing N 60 ±25 ––
Lever opereting force
Dozer blade N 30 ±8/25 ±8* ––
Rubber 118 to 128
Track tension Rubber pads mm 187 to 207 ––
Steel 187 to 207
Slew Bearing Play mm 0.5 ±0.4 2.0

* : Serial No. 125000535 or later

2-12
 2
SERVICE DATA
PERFORMANCE CRITERIA

Hydraulic pump assignment table

P4 P3 P2 P1

2DAA01Z

P1 Right travel, Boom, Bucket 58.3 L/min

P2 Left travel, Arm, Swing, Auxiliary line 58.3 L/min
P3 Slew, Dozer blade, Second auxiliary line 38.9 L/min
P4 Pilot pressure 10.8 L/min

Pump P1
Right travel Pressure: 21.0 MPa Test port P2
Boom Pressure: 21.0 MPa Test port P2
Bucket Pressure: 21.0 MPa Test port P2

Pump P2
Left travel Pressure: 21.0 MPa Test port P1
Arm Pressure: 21.0 MPa Test port P1
Swing Pressure: 21.0 MPa Test port P1
Auxiliary line Pressure: 21.0 MPa Test port P1

Pump P3
Slew Pressure: 19.6 MPa Test port P3
Dozer blade Pressure: 19.6 MPa Test port P3
Second auxiliary line Pressure: 19.6 MPa Test port P3

Pump P4
Pilot pressure Pressure: 3.4 MPa Test port P4

2-13
 2
SERVICE DATA
PERFORMANCE CRITERIA

Methods for inspecting performance ��

Hydraulic oil pressure (Main relief valve set pres- ��
sure) ��
Boom, Arm, Dozer Blade
Measuring Method
• Engine: Maximum R. P. M.
• Hydraulic oil temp.: 50~60°C
• Mount the pressure gauge on the pressure detection
port, operate the desired hydraulic circuit and measure
the relief pressure.
Pressure detection port
Circuit Relief valve
Port location Size
�������
Boom R1 P1
Arm R2 P2 G1/4
Blade R3 P3
��

�� �� �������

��

�� �� �������

Adjusting method
1. Loosen the locknut (2), and turn the setscrew (1) to
adjust the set pressure. �
• To increase the set pressure, turn the setscrew
�
clockwise.
• To decrease the set pressure, turn the setscrew
counterclockwise.
2. Upon completion of the adjustment, tighten the lock
nut (2) by holding the setscrew (1) to prevent it from
turning.
3. Operate the relief valve again to confirm that the newly
set pressure is stabilized.
�������

2-14
 2
SERVICE DATA
PERFORMANCE CRITERIA

Hydraulic oil pressure (Slewing relief valve set pressure) ��

Measuring method ��
• Engine: Maximum R. P. M. ��
• Hydraulic oil temp.: 50~60°C
• Mount the pressure gauge on the pressure detection
port and set a solid obstacle so that the upperstructure
cannot slew in the direction to be measured. Next, op-
erate the circuit to be measured and measure the relief
pressure.
Pressure detection port
Circuit Relief valve
Port location Size
Right slew R1
P3 G1/4 �������
Left slew R2

Adjusting method ��
It is not possible to adjust the set pressure with the relief
valve on the slew motor. If adjustment is required, replace
the relief valve assembly.

�� �������

Hydraulic oil pressure (Pilot pressure)

Measuring method
• Engine: Maximum R. P. M.
• Hydraulic oil temp.: 50~60˚C 2
1
• Mount pressure gauge on the pressure detection port
and measure the pilot relief pressure.
Pressure detection port
Relief valve
Port location Size
R4 P4 G1/4

P4 R4
2DAH041Z

Adjusting Method
1. Loosen the locknut (2), and turn the setscrew (1) to
adjust the set pressure.
• To increase the set pressure, turn the setscrew
clockwise.
• To decrease the set pressure, turn the setscrew
counterclockwise.
2. Upon completion of the adjustment, tighten the lock
nut (2) by holding the setscrew (1) to prevent it from
turning.
3. Operate the relief valve again to confirm that the newly
set pressure is stabilized.

2-15
 2
SERVICE DATA
PERFORMANCE CRITERIA

Travel speed (5 revolutions)

• Engine: Maximum R. P. M.
• Hydraulic oil temp.: 50~60°C
• Measurement posture: Excavator body raised using
both hoe attachment and dozer blade.
• Set crawler belts in motion. Starting after one full revo-
lution, measure the time required for 5 revolutions. (To
measure speed after it has stabilized.)

Travel speed (10m)

• Engine: Maximum R. P. M.
• Hydraulic oil temp.: 50~60°C
• Measurement posture: Travel posture
• Set excavator in motion. Starting after a distance of 5
meters, measure the time required to travel 10 meters.
Do this on level ground.

■ Travel posture
Fully extend the arm and bucket cylinders and adjust the
hoe attachment so that its lowest part is even with the ex-
cavator’s minimum ground clearance level. The hoe attach-
ment, of course, should be in a no-load state and the dozer
blade should not be touching the ground.

Straight-ahead travering
• Engine: Maximum R. P. M.
• Hydraulic oil temp.: 50~60°C
• Measurement posture: Travel posture
• Starting after an approach of 5 meters, drive the excava-
tor in a turn for 10 meters, then measure the distance of
X (5 m point). Do this on level ground.

2-16
 2
SERVICE DATA
PERFORMANCE CRITERIA

Natural travel drop

• Engine: Stopped
• Hydraulic oil temp.: 50~60°C
• Gradient: 15°
• Measurement posture: Fully extend the boom, arm and
bucket cylinders and completely retract the dozer blade
cylinder.
• With the excavator parked at angle for 5 minutes, mea-
sure the extent of natural drop.

Slew time
• Engine: Maximum R. P. M.
• Hydraulic oil temp.: 50~60°C
• Measurement posture: Completely retract the arm cyl-
inder, fully extend the bucket cylinder and adjust so that
boom foot pin and bucket pin are at matching height.
Rest the dozer blade on the ground.
• With the hoe attachment in a no-load state, wait 1 rota-
tion, then measure the time required for the next 2 rota-
tions.

Overrun when slewing stops

• Engine: Maximum R. P. M.
• Hydraulic oil temp.: 50~60°C
• Measurement posture: Same as that for measuring slew
time.
• Draw matching marks on the outer race of the slew
bearing and lower frame at an exactly 180 degrees rota-
tion from the starting point. With the hoe attachment in a
no-load state, rotate 180 degrees at, which point return
the operation lever to neutral. Measure the differential
between the position marks and the point the hoe at-
tachment stops.

Natural slew drop

• Engine: Stopped
• Hydraulic oil temp.: 50~60°C
• Gradient: 15°
• Measurement posture: Same as that for measuring slew
time.
• Rotate the upper machinery so that it is directly abeam
of the grade, then draw positional marks on the slew
bearing’s outer race and the lower frame. Then measure
the distance that develops between the marks after 5
minutes.

2-17
 2
SERVICE DATA
PERFORMANCE CRITERIA

Boom cylinder speed

• Engine: Maximum R. P. M.
• Hydraulic oil temp.: 50~60°C
• Measurement posture: Completely retract the arm cyl-
inder, fully extend the bucket cylinder and rest the dozer
blade on the ground.
• Then measure the time required for the bucket to reach
its highest elevation point (lowest point) from its lowest
point (highest point) resting on the ground. (Do not in-
clude the cushioning time.)

Arm cylinder speed

• Engine: Maximum R. P. M.
• Hydraulic oil temp.: 50~60°C
• Measurement posture: Completely retract the arm cyl-
inder, fully extend the bucket cylinder, position the arm
horizontally and rest the dozer blade on the ground.
• Then measure the time required for the arm cylinder to
completely retract (extend) from a fully extended state
(retracted state).

Bucket cylinder speed

• Engine: Maximum R. P. M.
• Hydraulic Oil Temp.: 50~60°C
• Measurement posture: Completely retract the arm cyl-
inder, position the arm horizontally and rest the dozer
blade on the ground.
• Then measure the time required for the bucket cylinder
to completely retract (extend) from a fully extended state
(retracted state).

Dozer blade cylinder speed

• Engine: Maximum R. P. M.
• Hydraulic oil temp.: 50~60°C
• Measurement Posture: Using the hoe attachment, lift up
the dozer blade end of the excavator.
• Then, raising and lowering the dozer blade full stroke,
measure the time required per stroke in each direction.

2-18
 2
SERVICE DATA
PERFORMANCE CRITERIA

Swing cylinder speed

• Engine: Maximum R. P. M.
• Hydraulic oil temp.: 50~60°C
• Measurement posture: Same as that for measuring slew
time.
• While swinging the boom left (right) to right (left), mea-
sure the time required for a full stroke each way.
(Do not include the cushioning time.)

Natural cylinder drop

Boom, arm, bucket, dozer blade, bucket tip
• Engine: Maximum R. P. M.
• Hydraulic oil temp.: 50~60°C
• Measurement posture: Completely retract the dozer
blade and arm cylinders, fully extend the bucket cylinder
and adjust the bucket pin position to the same height as
the boom foot pin.
• Maintain this position for 10 minutes, then measure the
change in rod length and the distance the bucket tip
falls.

Swing cylinder
• Engine: Stopped
• Hydraulic oil temp.: 50~60˚C
• Gradient: 15˚
• Measurement Posture: Same as that for measuring slew
time.
• Rotate the upper machinery so that it is directly abeam
of the grade, then measure the change in rod length
after 5 minutes.

Lever Operating Force

• With the engine stopped, attach a push-pull scale to the
center of the operation lever’s handle grip, or in the case
of a pedal, position a push-pull scale to its tip and record
the measurement at the point the lever/pedal reaches
full stroke.

2-19
 2
SERVICE DATA
PERFORMANCE CRITERIA

Lever Play
• Measure any discernible play at the tip of the lever (ped-
al).

Backlash
• Measurement Posture : Completely retract the arm cyl-
inder and fully extend the bucket cylinder.
• Move the tips of the bucket teeth from side to side (left
and right) and measure the play.

Slew Bearing Play

1. Unload the bucket, completely retract the arm cylinder,
fully extend the bucket cylinder, set the dozer blade
to the rear, and then adjust the boom foot pin and the
bucket pin so that they are the same height.
2. Place the dial gauge on the undersurface of the slew
bearing outer teeth located forward of the machine,
and then set the indicator to “0”.
3. Lowe the boom, raise the one side of the crawler by
around “H”, and then read the dial gauge.

Crawler Tension
• Raise the excavator completely off the ground using the
hoe attachment and dozer blade.
Then measure the distance (of droop) between the cen-
ter point on the crawler frame and top of the crawler
shoe.
Note: For the rubber crawler, the measuring should be
performed after placing the joint portion with “M” mark
to the top center.

2-20
 2
SERVICE DATA
TIGHTENING TORQUE

TIGHTENING TORQUE
Hydraulic hose

Tightening torque ���������

��������������
Hose fitting size Union nut (G) Taper thread (R) �����������������
N·m N·m
1/8 9.8 0
+4.9
11.8 ±1.2
������������
1/4 24.5+4.9
0 29.4 ±2.9 ������������
����������������
3/8 49.0 0
+4.9
53.9 ±5.4
1/2 58.8+4.9
0 88.3 ±8.8
3/4 117.7 0
+4.9
147.1 ±14.7
1 137.3+4.9
0 196.1 ±19.6 2EAA01Z

Bite-type pipe fitting for steel pipe

Tightening torque
Pipe outer diameter (mm)
N·m
8 34.3 ±4.9
10 41.7 ±2.5
12 58.8 ±4.9
15 88.3 ±4.9
16 93.2 ±4.9
18 132.4 ±4.9
22 205.9 ±9.8 2EAA02Z

27.2 245.2 ±9.8

28 313.8 ±19.6
32 313.8 ±19.6
35 411.9 ±19.6

2-21
 2
SERVICE DATA
TIGHTENING TORQUE

Joint for piping

Tightening torque
Nominal thread
Steel Cast steel
diameter
N·m N·m
1/8 11.8 ±1.2 10.8 ±1.1
1/4 29.4 ±2.9 24.5 ±2.5
3/8 53.9 ±5.4 49.0 ±4.9
1/2 88.3 ±8.8 73.5 ±7.4
3/4 147.1 ±14.7 127.5 ±12.7
1 196.1 ±19.2 171.6 ±17.2 2EAA03Z

Joint for piping (O-ring seal type)

Tightening torque ������

Nominal thread diameter (G) ������
N·m �������������
1/8 19.6 ±2.0
1/4 34.3 ±4.9
3/8 53.9 ±4.9
1/2 63.7 ±4.9
3/4 93.2 ±4.9
1 107.9 ±9.8
1-1/4 117.7 ±9.8 2EAA04Z

1-1/2 137.3 ±9.8

Tightening torque
Nominal thread diameter (UNF)
N·m
7/19-20 16.7 ±2.0
1/2-20 22.6 ±2.0
9/16-18 31.4 ±2.9
3/4-16 59.8 ±4.9
1-1/16-12 102.0 ±5.9
1-5/16-12 135.3 ±7.8
1-5/8-20 181.4 ±9.8

2-22
 2
SERVICE DATA
TIGHTENING TORQUE

Bolts and nuts (JIS strength category 10.9)

Tightening torque
Thread Size × pitch General tightening points Special tightening points
N·m N·m
M6 × 1.0 9.8 ±0.5 11.8 ±1.1
M8 × 1.25 22.6 ±1.1 26.5 ±2.5
M10 × 1.5 47.1 ±2.4 54.9 ±4.9
Coarse M12 × 1.75 83.4 ±4.1 97.1 ±7.4
M14 × 2.0 134.4 ±6.7 155.9 ±12.7
M16 × 2.0 207.9 ±10.4 241.2 ±17.2
M20 × 2.5 410.9 ±20.5 475.6 ±23.7
M8 × 1.0 24.5 ±1.2 28.4 ±1.4
M10 × 1.25 50.0 ±2.5 58.8 ±2.9
M12 × 1.5 87.3 ±4.3 102.0 ±5.1
Fine
M14 × 1.5 135.3 ±6.8 157.9 ±7.8
M16 × 1.5 220.6 ±11.0 256.0 ±12.7
M20 × 1.5 452.1 ±22.6 524.7 ±26.1

1. General tightening points (non-lubricated)

All securing points that have no special tightening
torque specified in this manual and that are not special
tightening points.
2. Special tightening points (grease with molybdenum di-
sulfide applied)
Points where a specific tightening torque is specified in
this manual.
3. Points where thread-locking compound should be ap-
plied (ThreeBond #1324).
4. If a tightening torque value is specified in this manual
for a point not listed in the table above, follow the spec-
ification in the manual.
5. To tighten multiple bolts and nuts evenly, alternately
tighten opposite bolts/nuts as a pair.

2-23
 2
SERVICE DATA
TIGHTENING TORQUE

2-24
 2
SERVICE DATA
HYDRAULIC CIRCUIT DIAGRAM

HYDRAULIC CIRCUIT DIAGRAM

Equipped with options 1/2

2-25
 2
SERVICE DATA
HYDRAULIC CIRCUIT DIAGRAM

Equipped with options 2/2

2-26
 2
SERVICE DATA
HYDRAULIC CIRCUIT DIAGRAM

Equipped with angle blade and blade float 1/2

2-27
 2
SERVICE DATA
HYDRAULIC CIRCUIT DIAGRAM

Equipped with angle blade and blade float 2/2

2-28
 2
SERVICE DATA
HYDRAULIC CIRCUIT DIAGRAM

Equipped with high-flow (option) 1/2

2-29
 2
SERVICE DATA
HYDRAULIC CIRCUIT DIAGRAM

Equipped with high-flow (option) 2/2

2-30
 2
SERVICE DATA
HYDRAULIC CIRCUIT DIAGRAM

Equipped with high-flow, angle blade, blade float (option) 1/2

2-31
 2
SERVICE DATA
HYDRAULIC CIRCUIT DIAGRAM

Equipped with high-flow, angle blade, blade float (option) 2/2

2-32
 2
SERVICE DATA
ELECTRIC CIRCUIT DIAGRAM

ELECTRIC CIRCUIT DIAGRAM

First auxiliary hydraulic piping with on/off switch

2-33
 2
SERVICE DATA
ELECTRIC CIRCUIT DIAGRAM

First auxiliary hydraulic piping with proportional control

2-34
 2
SERVICE DATA
ELECTRIC CIRCUIT DIAGRAM

First auxiliary hydraulic piping with on/off switch, second auxiliary hydraulic piping with bucket select switch

2-35
 2
SERVICE DATA
ELECTRIC CIRCUIT DIAGRAM

First auxiliary hydraulic piping with proportional control, second auxiliary hydraulic piping with bucket select switch

2-36
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

WIRE HARNESS WIRING DIAGRAM

Upper frame wiring 1/2 Upper frame wiring 2/2
Serial No. 125000001 to 125000849

1. Control unit 1. Plate

2. Wire harness (03942-26630) 2. Flip flop unit
3. Fusible link 3. Relay
4. Diode 4. Relay
5. Fuse box 5. Resistance
6. Short connector 6. Relay
7. Wire harness (03742-17070) 7. Controller
8. Plate 8. Buzzer
9. Short connector 9. Timer
10. Horn 10. Safety relay
11. Relay 11. Diode unit
12. Wire harness (03742-05600)

2-37
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

Upper frame wiring 2/2

Serial No. 125000850 or later

1. Plate
2. Flip flop unit
3. Relay
4. Relay
5. Resistance
6. Relay
7. Controller
8. Buzzer
9. Timer
10. Safety relay
11. Diode unit

2-38
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

Upper frame wiring (first auxiliary hydraulic piping with proportional control) Upper frame wiring (first auxiliary hydraulic piping with proportional control and foot switch)

1. Wire harness (03942-26910) 1. Wire harness (03742-19410)

2. Wire harness (03742-17510) 2. Wire harness (03742-17510)

2-39
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

Upper frame wiring (first auxiliary hydraulic piping with on/off switch and foot switch) Upper frame wiring (equipped with angle blade)

1. Wire harness (03742-19310)

1. Wire harness (03742-23010)

2. Diode
3. Flip flop unit
4. Relay
5. Relay

2-40
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

Control unit (second auxiliary hydraulic piping with bucket select switch) Control unit (first auxiliary hydraulic piping with on/off switch)

1. Wire harness (03570-15570) 1. Resistance

2. Diode 2. Relay
3. Relay 3. Wire harness (03942-26810)
4. Flip flop unit

2-41
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

Control unit (Air conditioner) Control unit (travel alarm)

1. Relay
2. Wire harness (03942-27110)
3. Diode
4. Buzzer

1. Control amplifier
2. Relay (Air conditioner)
3. Relay (Compressor)
4. Wire harness (03946-21310) (Serial No. 125000001 to 125000939)
Wire harness (03946-21320) (Serial No. 125000940 or later)
5. Short connector
6. Compressor
7. Control box
8. Air conditioner unit
9. Solenoid valve

2-42
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

Control unit (arm holding limit) Control unit (automatic deceleration)

1. Relay 1. Wire harness (03742-17710)

2. Wire harness (03760-15590) 2. Diode
3. Diode 3. Relay
4. Timer unit
5. Flip flop unit
6. Relay

2-43
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

Control unit (heater for cold climate)

1. Control amplifier
2. Relay
3. Wire harness (03745-08250) (Serial No. 125000001 to 125000939)
Wire harness (03745-08260) (Serial No. 125000940 or later)
4. Short connector
5. Control unit
6. Heater

2-44
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

Auxiliary piping detent (first auxiliary hydraulic piping with on/off switch) Auxiliary piping detent (first auxiliary hydraulic piping with proportional control)

1. Wire harness (03742-19450) 1. Wire harness (03742-19440)

2. Relay 2. Relay
3. Flip flop unit 3. Flip flop unit

2-45
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

2-46
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

2-47
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

2-48
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

2-49
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

2-50
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

2-51
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

2-52
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

2-53
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

2-54
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

2-55
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

2-56
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

2-57
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

2-58
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

2-59
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

NO. STANDARD NAME

2-60
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

2-61
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

2-62
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

2-63
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

2-64
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

2-65
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

2-66
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

2-67
 2
SERVICE DATA
WIRE HARNESS WIRING DIAGRAM

2-68
 FUNCTION 3
Piston pump ................................................................ 3-2
Gear pump .................................................................. 3-5
Control valve................................................................ 3-6
Pilot valve .................................................................. 3-12
Proportional control solenoid valve............................. 3-13
Emergency shut-off valve........................................... 3-14
CylinderS ................................................................... 3-15
Travel motor .............................................................. 3-16
Slew motor ................................................................ 3-20
Swivel joint ................................................................ 3-24

3-1
 3
FUNCTION
PISTON PUMP

PISTON PUMP
Operation
This pump is a variable displacement piston pump
with a single cylinder block, which discharges two
equal volumes.
Ten pistons (2) are installed in the cylinder block
(1), and the end surface is in contact with the valve
plate (3). The suction port C and the discharge port A
of the pump P1 and the discharge port B of the pump
P2 are arranged in the valve plate (3). On the other
hand, the swash plate (4) is fastened to the hous-
ing at a given inclination, and the pistons (2) rotate
along this swash plate (4).
When the shaft (5) is rotated, the cylinder block (1)
rotates, the pistons (2) in the cylinder block execute
reciprocating movement along the swash plate (4),
and the pump executes suction and discharge. At this
time, the pistons in contact with the discharge port A
of the valve plate (3) operate as the pump P1, while
the pistons in contact with the discharge port B oper-
ate as the pump P2.
In this way, the ten pistons (2) execute one suction
and discharge stroke with each revolution of the
cylinder block (1), so that suction and discharge are
executed continuously when the shaft (5) is rotated
continuously.
As the piston stroke displacement depends on the
inclination of the swash plate (4), the discharge flow
quantity can be changed by changing the inclination
of the awash plate (4).

Discharge volume control

The swash plate (4) is equipped with the bearings
(6) and is mounted on the housing at an inclination
that can be varied. The swash plate (4) is loaded
with the pistons (9) and the piston (10) in opposi-
tion to the spring (7). The discharge pressures from
the pumps P1 and P2 work on the pistons (9). The
discharge pressure from the pump P3 works on the
piston (10). When the discharge pressure is below
the value preset for the spring (7), the inclination of
the swash plate (4) is fixed to the maximum value by
the spring (7).

3-2
 3
FUNCTION
PISTON PUMP

When the discharge pressure exceeds the set value

of the spring (7), the swash plate (4) is pushed by
the pistons (9) and (10), the inclination decreases,
and the swash plate is kept at an inclination where
the discharge pressure and the spring force are bal-
anced.
When the pressure acting onto the pistons (9) and
(10) increases still further, the inclination of the
swash plate (4) becomes still smaller. The until now
inactive spring (8) also becomes active, and a still
higher discharge pressure will be required to coun-
teract this spring force.
In this way, the inclination of the swash plate (4)
is changed, the discharge quantity is controlled, the
pump is supplied only with the pressure and the flow
volume required for the load, and the pump loss
pressure is reduced.
As the inclination of the swash plate (4) changes
not only according to the operation pressure of the
pumps P1 and P2, but also according to the opera-
tion pressure of the pump P3, the P-Q curve of the
piston pump becomes a curve with effective use of
the engine power (full power control).

3-3
 3
FUNCTION
PISTON PUMP

Relief valve and solenoid valve � �

��
If the oil pressure discharged from the pump P4 (2) be-
comes higher than the set value, the relief valve (1) releases
� ��
the oil into the tank circuit. In this way, the relief valve (1)
keeps the pressure in the pilot circuit constant.This pilot � �
pressure is turned of or off by the solenoid valve A, used
to switch the 2nd speed, and the solenoid valve B, used to
switch the lever lock.

��������

Solenoid valve
When the solenoid valve is not energized
The oil in the port P is blocked by the spool (1).
Since the port A is connected with the port T, the pressure
in the downstream pilot circuit becomes equal to the tank �
pressure.

� �

�
��������

When the solenoid valve is energized

A magnetic field is generated around the coil that causes
the plunger (2) to be pulled downward and the spool (1)
to be pushed down. In this way, the oil in the port A flows
to the port A, transferring the pressure to the downstream �
pilot circuit.

�
�

� ��������

3-4
 3
FUNCTION
GEAR PUMP

GEAR PUMP 3 1

The gear pump is composed of two mutually engaging

gears (drive gear (1) and driven gear (2)) contained in a gear
case. When the drive shaft (3) is rotated, the space be-
tween the case and the gears is filled with oil that is flowing
from the inlet to the outlet.
������� ���������
����������� �����������
���������� ���������

2 3IAB01Z

3-5
 3
FUNCTION
CONTROL VALVE

CONTROL VALVE T 1

When the spools are in the neutral position:

When the control valve spools are not moved, the oil flows
through the center bypass passage (1) and the tank pas-
sage T to return to the tank, as shown by the arrow.

3JAA01Z

When the spool is operated:

When the spool is moved to the right: 4
When the spool (2) is moved to the right, the center bypass
A B
passage (1) is closed and the oil that has flowed into the
valve from the pump passes through the parallel passage
(4), the load check valve (5), the port A, and to the actua-
tor.
On the other hand, oil returning from the port B returns to 5
the tank through the tank passage T.

3 T 2
3JAA02Z

Load check valve � �

While the spool switching operation is being performed,
this valve prevents oil from flowing backward due to the
load pressure C coming from the actuator port.

��������

3-6
 3
FUNCTION
CONTROL VALVE

Main relief valve

The main relief valve is mounted between the pump circuit
and tank circuit of each inlet housing, and serves to main-
tain the circuit pressure at the set value.

The relief valve remains turned off:

As long as the pressure in the circuit is lower than the set � � � �
value, the relief valve maintains a pressure equilibrium and
thus remaining turned off. The hydraulic pressure from the
pump flows through the chamber C and the orifice of the
main poppet (2) to enter the chamber D and the needle
valve (1). On the other hand, the forces F and F1 are acting � ��
in the arrow directions on both sides of the main poppet
(2).
F=PxA
F1 = P x A1 (P: Pressure A and A1: Cross-sectional areas)
The cross-sectional area A1 is larger than the cross-sec- � ��
tional area A, and thus the main poppet 82) is pushed to ��������

the left seat surface by the force of “F1 - F”.

The relief valve is actuated:

If the pressure in the circuit becomes higher than the set
force of the spring (3), the needle valve (1) is pushed to the
2 3 1
right by hydraulic pressure and the oil flows into the tank
passage T. When this happens, a pressure differential is
generated between the two ends of the orifice of the main
poppet (2), and the main poppet is pushed to the right by
the hydraulic pressure. As a result, the pressure oil in the
circuit flows into the tank passage as shown by the ar-
rows.
This operation maintains the pressure in the circuit at the
set value.
T
3JAA05Z

Port relief valve

The port relief valve is located between the actuator and
the tank circuit T. It protects the actuator from a pressure
shock caused by the sudden blocking of the actuator port
or by overloading, or absorbs abnormal pressure caused
by an external force.

Relieving operation:
� � �� �
When the pressure in the circuit is lower than the set value,
the relief valve maintains a pressure equilibrium. The hy-
draulic pressure from the pump passes from the chamber
B to the orifice of the piston (4), then reaches the chamber
C and the needle valve (5).
On the other hand, the forces F and F1 are acting in the ar-
row directions on both sides of the main poppet (6).
F=PxA
F1 = P x A1 (P: Pressure A and A1: Cross-sectional areas)
The cross-sectional area A1 is larger than the cross-sec-
tional area A, and thus the main poppet (2) is pushed to the
� � �
left seat surface by the force of “F1 - F”. ��������

3-7
 3
FUNCTION
CONTROL VALVE

If the pressure in the circuit becomes higher than the force T 7

of the spring (7), the needle valve (5) is pushed to the right
by hydraulic pressure, connecting the high-pressure area
with the tank passage T. The oil then flows around the cir-
cumference of the needle valve (5) and passes through the
slits, flowing into the tank passage T.

5 3JAA07Z

When the needle valve (5) is pushed to the right to con- T C

nect the high-pressure area with the tank passage T, the
pressure on the back side of the piston (4) drops and the
piston (4) is pushed to the right against the needle valve
(5).This shuts off the flow of hydraulic oil flowing from the
chamber B to the chamber C, resulting in a low pressure in
the chamber C.

4 6 5 3JAA08Z

If the pressure of the chamber C becomes lower than that B T C

of the chamber B, equilibrium cannot be maintained. As a
result, the main poppet (6) opens to allow the hydraulic oil
to flow into the tank passage T.

6 3JAA09Z

Suction operation: B A A1
If the cylinder is operated at a speed too fast for the oil
supply to keep up, and thus the pressure of the chamber B
becomes almost negative, the oil from the tank is supplied
to prevent cavitation.
When the pressure in chamber B is lower than the pressure
in the tank passage T, the difference in the sectional areas
of A and A1 causes the main poppet (6) to open. Then,
oil to fill the space in the chamber B enters from the tank
passage T.

T 6 3JAA10Z

3-8
 3
FUNCTION
CONTROL VALVE

Anti-cavitation valve
This valve is installed between the cylinder port and the
tank passage. If the cylinder is operated at a speed too fast
for the oil supply to keep up with, and thus the pressure of
the cylinder port becomes negative, the oil from the tank is
supplied to prevent cavitation.

Normally, the cylinder port (P) is under the pressure and � �

thus the poppet (1) is closed. If the negative pressure is � �
generated in the cylinder port (P) and its pressure becomes
lower than the tank passage (T), the oil pushes the poppet
(1) and flows through the tank passage (T) into the cylinder
port (P).

��������

Anti-drift valve
This valve is installed in the head side of the cylinder cir-
cuit of the boom section, and it prevents oil leakage in the
cylinder head circuit and decrease the natural drop of the
boom.

When the spool is in the neutral position ��

The pressure in the cylinder port is directed to the spring � �
chamber (5) via the passage (2), the hole on the spool (3)
and the passage (4). The spring force and the pressure dif- �
ference between the poppet areas pushes the seat surface ��
of the poppet (1) against the seat surface of the valve body.
Therefore, the oil flow is blocked in this section.

� � � ��������

When the Boom Raise operation is performed ��

The oil supplied from the pump pushes open the poppet
(1), and then flows into the cylinder port.
�
��

� ��������

3-9
 3
FUNCTION
CONTROL VALVE

When the Boom Lower operation is performed ��

When the Boom Lower operation is performed, the pilot
pressure is led to the port P1 to push down the spool (3). �
This allows the oil in the spring chamber (5) to flow through �
the passage (4) and into the port Dr (tank port). As a result,
��
the poppet (1) is kept opened and the return passage is
secured.

� � � ��������

Switch valve
This valve switches among the circuits of bucket, arm,
boom, swing and service when any of them is activated
during traveling. The combined control of straight travel
and other operation can be done, because the oil supplied
by the pump P3 is directed to the section other than the
travel section.

When the switch valve is activated

When the traveling operation and other operation are per- � � �
formed at the same time, the pilot pressure is directed tot
� �
the port P1 to push up the spool (1). This allows the oil
entered the port P to flow through the parallel passage (2),
��
the spool head and the second parallel passages A and B.
Since the second parallel passage A is connected to the
boom and the bucket sections, while the second parallel
passage B is connected to the arm and the swing sections,
the combined operation of traveling and other operation
can be achieved.
�
��������

When the switch valve is not activated

� �
The spool (1) is not switched because the pilot passage
(2) is open to the tank passage and thus the pressure in
� �
the pilot chamber (3) is equal to the pressure in the tank.
Thus, the oil entered the port P flows into the center bypass
��
passage (3). Also, part of the oil flows through the parallel
passage (2), dozer blade and slew sections.

�
��������

3-10
 3
FUNCTION
CONTROL VALVE

3-11
 3
FUNCTION
PILOT VALVE

PILOT VALVE 1
The pilot valve casing contains the vertical shaft holes that 2
incorporate the reducing valves. When the lever is tilted,
the push rod and spring seat are pushed down, changing
the spring force of the secondary pressure.
The casing contains the oil inlet port P (the primary pres- A B
sure) and the tank port T. The secondary pressure corre- P T
sponding to the changes in operating angle performed by
the lever (1) can be provided through the output ports A
and B located below the vertical shaft holes. The second-
ary pressure functions as the pilot pressure to actuate the
spool of the control valve (2). 3KAC01Z

When the lever (1) is at the neutral position:

The force of the spring (3) that determines the output pres-
1
sure (secondary pressure) of the pilot valve is not conveyed T
to the spool (4). Therefore, the spool (4) is pushed up by
the return spring (5), and the output ports A and B are con-
nected with the tank port T, making the pressures in the
3
ports A and B equal to the pressure in the tank port T.
5
4

P
A B 3KAC02Z

When the lever (1) is tilted:

1
When the lever (1) is tilted and the push rod (6) is pushed,
the spool (4) moves downward and the input port P is con- 6
nected with the output port A. Then, the oil from the pilot
pump flows into the output port A, generating a pressure.

P
A B 3KAC03Z

When the lever (1) is kept at a certain position:

1
When the lever (1) is tilted and thereby the pressure in the
output port A increases to the level equivalent to the force
of the set spring (3) force, the hydraulic pressure becomes
balanced with the spring force. When the pressure in the
output port A becomes higher than the set force, the out-
put port A and the input port P are closed, while the output 3
A and the tank port T are opened. When the pressure in the
output port A becomes lower than the set force, the output
T
port A and the input port P are opened, while the output
port A and the tank port T are closed. Thus, the secondary
pressure is kept constant. P
A B 3KAC04Z

3-12
 3
FUNCTION
PROPORTIONAL CONTROL SOLENOID VALVE

PROPORTIONAL CONTROL SOLENOID VALVE

This valve controls the secondary pressure by using the S 1
built-in proportional pressure reducing valve. 2 4
The secondary pressure generated corresponds to the S=A1-B1
changes in current, because the force used to generate the
secondary pressure is applied to the solenoid according to B1 A1
the current passing through the coil.
Fk
When a current flows in the solenoid, a thrust force propor- Fs Fks
tional to the current is generated and it pushes the spool Paxs

(1) so that the oil supplied from the port P is directed to the
secondary pressure side port A to increase the pressure
Pa in the port A. P A T
This pressure Pa works on the differential area S between
Paxs Fk Fs Fks
the cross sections A1 and B1 of the spool (1), and the spool 3KAD01Z

(1) is pushed to the solenoid side by the oil pressure Pa x S.

The spool (1) stops at the position where the sum of the oil
pressure Pa x S and the force Fk exerted by the springs (2)
is balanced with the thrust force Fs generated by the sole-
noid. The weight Fks of the spring (4) for fine adjustment of
the secondary pressure works in the direction (left) to assist
the thrust force from the solenoid.

When the thrust force becomes larger than the set value,
the spool (1) is moved to the left, connecting the port P
(supply side) and the port A (secondary side) through the 5 1
notch (5).

P A T

3KAD02Z

When the thrust force becomes smaller than the set value,
the spool (1) is moved to the right, connecting the port A 1 6
(secondary side) and the port T (tank side) through the
notch (6).
Therefore, the opening areas of the supply side notch (5)
and discharge side notch (6) are controlled by the move-
ment of the spool (1), and secondary (pilot) pressure cor-
responding to the thrust force generated by the solenoid
can be provided.

P A T

3KAD03Z

3-13
 3
FUNCTION
EMERGENCY SHUT-OFF VALVE

EMERGENCY SHUT-OFF VALVE

This valve prevents the boom or arm being raised from fall-
ing. If the hydraulic hose breaks, the valve shuts off the
oil flow pushed back from the cylinder and prevent it from
further flowing.

When the boom or arm is raised, the pressure oil from the
hydraulic pump flows through the port V to push up the
check valve (1) and then through the port C into the boom
or arm cylinder.

� �

��

�
��������

When the boom or arm is lowered, the pilot pressure from

the pilot valve (2) is led to the port Pi. The pilot pressure
from the port Pi works on the spool (3) to push it up. The �
return oil from the cylinder flows from the port C to the pas-
sage through the spool (3) and the check valve (1), the port �
V and into the tank passage.

��

� �

� ��������

The boom or arm does not fall even if the hydraulic hose
breaks, because the oil flow leading to the head side of the
cylinder is blocked and isolated in the passage through the
check valve (1) and the spool (3).
�
�

��

� �
��������

3-14
 3
FUNCTION
CYLINDERS

CYLINDERS
The pressure oil alternately flowing into the piston through
the outlet and inlet on both sides (head and rod sides)
causes the piston to perform the reciprocating motion.
For those cylinders with a cushion mechanism, the shock
resulting from the piston colliding with the cover at the
stroke end is dampened by the mechanism.

Cushion mechanism

1 3 4 2

3LAA01Z

1 3 4 2

3LAA02Z

When the piston (1) approaches the stroke end and is likely
to bump into the cover (2), the cushion bearing (3) that is
moving ahead of the piston enters the cushion seal (4).
This shuts off the return passage for the hydraulic oil on the
back of the piston, and thus the oil is expelled only from the
throttle hole or the groove provided in the cushion bearing
(3). This causes the piston (1) backpressure to increase,
slowing the piston speed.

3-15
 3
FUNCTION
TRAVEL MOTOR

TRAVEL MOTOR F1
3 1 2 5 4 F2
Hydraulic motor F
The cylinder block (1) is constructed with the pistons (2),
F
and its end surface comes in contact with the valve plate
(3) containing two half-moon-shaped ports (B) and (C). The F2
cylinder block (1) rotates freely and is connected to the D F
shaft (4) via the splines. On the other hand, the swash plate
(5) is fixed to the housing. F2
B C
When the high-pressure oil is directed to the port B, the
F F2
pistons (2) push the swash plate (5) with the force F per
piston. ������
���������
F = P x A P: Pressure A: Piston sectional area ����� 3MAA01Z

The force F used to push the swash plate (5) by the pistons
(2) is divided into two: the force F1 that pushes the plate
and the force F2 that rotates the cylinder block (1).
A rotational force is generated in the cylinder block (1) by
the total sum of the rotational forces in the high-pressure
side piston, and via the splines the torque is transmitted to
the shaft (4) to turn it. On the other hand, if the high-pres-
sure oil is directed to the port C, the rotation is the reverse
of the above.

Counter balance valve � �

When the high pressure oil is directed into the port P1, the
oil pushes up the check valve (6), flows into both the motor
port M1 and the chamber B in the pilot section. The pres- �� ��
sure oil flows into the motor from the motor port M1. On the
other hand, the return oil from the motor does not flow into
the port P2, because the passage between the motor port
M2 and the port P2 is blocked by the check valve (6). This
increases the pressure in the port P1 and the chamber B.
When the pressure in the chamber B becomes higher than
the set value for the spring (7), the spool (8) is moved to the
left so that the motor port M2 is connected with the port �� ��

P2. As a result, the motor starts running. � � ��������

If the motor becomes too fast and the volume of oil flowing � �
out of the motor port M2 becomes larger than that of flow-
ing into the motor port M1, the pressure in the port P1 and
the chamber B drops. When the pressure in the chamber �� � ��
B becomes lower than the set pressure value, the spool
(8) returns to the right. As a result, the flow of the return oil
is narrowed down at the section D to generate the back
pressure in the motor port M2 and to slow down the motor
speed. If the motor speed becomes slower, the pressure
in the port P1 and the chamber B is increased again to
cause the spool (8) to move to the left. The back pressure
generated in the motor port M2 is eliminated. In this way, �� ��
the motor is controlled to run at the speed proportional to � ��������

the oil flow entered.

3-16
 3
FUNCTION
TRAVEL MOTOR

When the high pressure oil directed to the port P1 is shut � � �

off, the pressure in the port P1 becomes equal to that of
the port P2 and the spool (8) returns to the neutral posi-
tion. This pushes out the oil in the chamber B to the port �� ��
P1 side. At this time, the oil flow is narrowed down at the
orifice (9), and thus the spool (8) is slowly returned to the
neutral position. In this way, the motor can be stopped
without having a shock.

�� ��
� ��������

2-speed mechanism � �
�� ��
2nd speed control valve
When the high pressure oil is directed to the motor port
M1 and the travel 2nd speed solenoid valve (1) is at the 1st
speed side position, the pressure in the chamber C is low
because it is connected to the tank passage via the 2nd
�
solenoid valve (1). For this reason, the spool (2) is pushed
to the left by the spring (4), and the piston chamber (3) �
that controls the swash plate becomes connected to the
tank port (T). There is no force pushes the swash plate (5)
upward.

� ��������

When the travel 2nd speed solenoid valve is switched to �

the 2nd speed side position, the pressure oil from the travel �� ��
2nd speed solenoid valve (1) flows into the chamber C to
move the spool (2) to the right. When the spool (2) is moved
to the right, the motor port M1 is connected to the port A,
and the motor port M2 is connected to the port B. This al-
lows the pressure oil from the motor port M1 to move the �
shuttle spool (12) to the right and to flow into the piston
chamber (3) that controls the swash plate. Also, the control �
piston (11) is activated to push up the swash plate (5). �
��
Since the pressure oil is not supplied when the engine is
�
stopped, the spool (2) is returned to the 1st speed position
by the spring (4). � ��������

3-17
 3
FUNCTION
TRAVEL MOTOR

Swash plate �
The swash plate (5) has three planes of A, B and C, as �
shown in the figure, and it is mounted to the flange holder
(6) in such a way that its angle of inclination to the flange �
holder (6) can be changed by means of the two steel balls
(7). �
� �
When the 2nd speed control valve is switched to the 1st
speed side, the swash plate control piston chamber (3) is � �� �
connected to the tank port. Also, the swash plate (5) is
��
stabilized at the surface “A” by the forces of the piston as-
sembly (8), resulting in the angle of “α” that can run the
motor at the 1st speed. �
��������

When the 2nd speed control valve is switched to the 2nd

speed side, the swash plate control piston chamber (3)
is connected to the motor drive pressure port. Also, the
swash plate (5) is stabilized at the surface “B” due to the
equilibrium between the force of the springs (9), (10) and
the force of the 2nd speed control piston (11), resulting in
the angle of “β” that can run the motor at the 2nd speed.
When the engine is stopped, the pilot pressure of the 2nd
speed control valve is cut off, so the swash plate (5) is sta-
bilized at the surface of “A” with the angle of “α”, resulting
in the 1st speed side. For this reason, when starting the
engine, the motor always is set to the 1st speed.
��������

Automatic 2-speed switching system

When a load greater than the set value is applied to the
travel motor during traveling in the 2nd (high) speed, the hy-
draulic pressure working on the counter balance, passage
(1) and the valve becomes high. This moves the valve (2) to ��
the left. Once the valve (2) is moved to the left, the pressure
oil that has been flowing through the shuttle valve (12) and � �
� �
the valve (2) to work on the piston (11) is now flowing into
the tank passage. The piston (11) returns, and the motor is
switched to the 1st (low) speed.

�� ��������

3-18
 3
FUNCTION
TRAVEL MOTOR

Parking brake
The friction disc (2) and the disc (1) are connected through
the spline. The friction disc (2) and the disc (1) are pressed
against the flange holder (6) by the springs (4) via the brake
piston (5). The friction force between these discs gener-
ates the brake torque to prevent the cylinder block (3) from
rotating.

3 6 2 1 5 4
3MAA04Z

When the pressure oil is dorected into the motor, the oil
flows from the parking brake release port (7) into the brake
piston chamber (8). The oil pressure overpowers the spring
force and moves the brake piston (5) to the right. This gen-
erates a clearance between the friction disc (2) and the disc
(1) to release the parking brake function. Once the motor
stops, no pressure oil flows into the parking brake release
port (7) and the parking brake force is operated by the
spring (4).

2 1 8 7 5 4
3MAA05Z

Reduction gears 7 6 4 1
The reduction gears consist of 2-stage simple planetary
gears connected in series. Each planetary gear consists
of a sun (input) gear, an internal tooth ring gear and planet
gears mounted on a carrier. The sun gear “floats” within the
planet gears so as to attain uniform load distribution at the
multiple gear mesh points.
The motor drives the 1st stage sun gear (1) which in turn
drives the 1st planet gears (2). Since these planet gears (2)
are engaged with the ring gear (3), the rotation is transmit-
ted to the 1st stage carrier (4).
The 1st stage carrier (4) is coupled directly to the 2nd stage
sun gear (5) which in turn drives the 2nd planet gears (6). 5 3 2 3MAA08Z

The 2nd stage carrier (7) is a part of the motor housing

(non-rotating) and thus the main torque is output to the ring
gear (3). The output flange rotation is opposite to the input
rotation.

3-19
 3
FUNCTION
SLEW MOTOR

SLEW MOTOR F1
3 1 2 5 4 F2
Hydraulic motor F
The cylinder block (1) is constructed with the pistons (2),
F
and its end surface comes in contact with the valve plate
(3) containing two half-moon-shaped ports B and C. The F2
cylinder block (1) rotates freely and is connected to the D F
drive shaft (4) via the spline. On the other hand, the swash
plate (5) is fixed to the housing. F2
B C
When the high-pressure oil is led to the port B, the pistons
F F2
(2) push the swash plate (5) with the force F per piston.
F = P x A P: Pressure A: Piston sectional area ������
���������
The force F used to push the swash plate (5) by the pistons ����� 3MAA01Z

(2) is divided into two: the force F1 that pushes the plate
and the force F2 that rotates the cylinder block (1). The total
sum of the components in the direction of rotation of the
high-pressure side piston generates a rotational force in the
cylinder block (1), and via the spline, the torque is transmit-
ted to the shaft (4), turning it. Conversely, if high-pressure
oil is introduced to the port C, the rotation is the reverse of
the above.

Relief valve
This relief valve is equipped with shockless function and
works in two stages.

The 1st stage

When the relieving operation starts, the pressure P1 in the �� � �� �� � �
chamber B is kept low, while the pressure P in the chamber
M becomes high due to the oil flowed into it.
At this time, there are two forces acting on the poppet (10):
the force F which moves the poppet (10) to the left, the
force (F1) which pushes seat against the right side. Since F
�� �
= P x A, F1 = P1 x A1, P > P1 and A > A1, the poppet (10)
is moved to the left by this force “F-F1”, and the pressure
is released from the chamber M through the passage in the
�� �
supply side. That is, during the time piston (11) is moving to
its stroke end, the relief valve operates at low pressure.
��������

The 2nd stage

When the piston (11) reaches the stroke end, the pressure �� � �� �� � �
in the chamber B increases and becomes equal to that of
the chamber M. At this time, the force moving the poppet
(10) to the left side becomes “P = P1” and thereby “A-A1”.
This allows the relief valve to operate at the specified set
pressure.
�� �

�� �

��������

3-20
 3
FUNCTION
SLEW MOTOR

Make-up valve
The makeup valve has two functions:
One function is to prevent the slewing structure from run-
ning away by preventing the cavitation caused by overrun
of the piston motor.
The inertia of the slewing mechanism rotates the motor,
pumping up the oil. When this rotational speed exceeds
the rotational speed achieved by the oil volume supplied to
the motor, the shortfall in oil volume is replenished through
the makeup valve (1) to the motor main circuit to prevent a
vacuum from being generated in the circuit.
The other function is to obtain the normal braking function
by keeping the circuit in the normal state. When the circuit � ��������

between the motor and the control valve is closed, as in

braking, the oil from the motor drain, as well as the leak
from the valve, is replenished through the makeup valve (1)
to prevent a vacuum from being generated in the circuit.

Anti-rebound valve
When the motor is stopped, it is prevented from rebound-
ing due to the accumulated pressure, by connecting the
main circuit of the motor to the make-up circuit for a certain
period.

When the brake is actuated � �

The braking pressure generated at the port Pv1 moves the
check valve (2) to the right until it is pushed against the sec-
tion B. Thus, the oil flow is blocked at the section B.

��� �� ���

��������

When the Motor Rebounds

When the motor is stopped by braking operation of the
brake valve, it starts rebounding due to the accumulated
pressure in the main circuit. This rebound pressure gener-
ated at the port Pv2 moves the sleeve (3) to the left to open
the passage. The rebound pressure is released from the
port Cv.

��� �� ���

� �
��������

3-21
 3
FUNCTION
SLEW MOTOR

The rebound pressure also pushes the check valve (1) to � �

the left, which is the opposite direction when braking. The
flow control valve built in the check valve (2) (that is now
on the lower pressure side) releases the oil in the damper
chamber (4) at a constant flow rate. Therefore, the check
valve (1) moves at a constant speed
When the check valve reaches its stroke end, the passage
from the port Pv2 to the port Cv is closed.

��� �� ���

� ��������

Parking brake
The cylinder block (1) and the disc (1) are connected through
�
the spline. The disc (2) is pushed between the brake piston
(4) and the case (5) by the spring (3), and a brake force is �
�
generated by this arrangement, which is stopping the cyl-
inder block (1) from turning.
�

� ��������

When the oil is directed from the parking brake release port
to the brake piston chamber (6), the oil pressure overpow-
ers the spring force and moves the brake piston (4) to the
left. This generates a clearance between the disc (2) and �
the case to release the parking brake function.

� �

��������

3-22
 3
FUNCTION
SLEW MOTOR

Timer valve � �
This valve is used to prevent sudden operation of the park- ��
ing brake when the motor is stopped. ��
When the parking brake is activated, the pressure oil from
the port P4 is supplied at all times to the port PG, the spool
(1) is pushed to the right by the spring (2) force, and the
port PG is closed
When the slew pilot pressure or arm pilot pressure is di-
rected to the port SH, the force to move the spool (1) over- ��
comes the spring (2) force, and thus the spool (1) is move
to the left to open the port PG. The pressure oil from the
port PG flows through the hole at the center of the spool
(1) and the parking brake release port (PB) to release the ��������

parking brake operation.

When the pilot pressure in the port SH disappears, the

spool (1) is moved to the right by the spring (2) force, the �� �
port PG is closed, and the oil in the brake piston cham- ��
ber (3) is blocked. This enclosed oil gradually flows into the ��
drain port (dr) from the orifice located at the outer circum-
ference of the spool (1). As a result, the timer valve is used
as a timer, and thereby the parking brake does not start
working rapidly. It starts working after a certain time.
� �

��������

Reduction gears �
The reduction gear is composed of a 2-stage planetary
gear mechanism, and it converts the high-speed operation � �
of the motor to the low speed torque to obtain the rota-
tional force of the pinion shaft (1).
In the figure on the right, the drive force transmitted from �
�
the motor output shaft is transmitted to the second stage
sun gear (5) via the first stage drive gear (2), the planetary
gear (3) and the carrier 1 (4). �
The drive force is transmitted in the same way to the pinion
shaft (1) via the second stage sun gear (5), the planetary �
gear (6) and the carrier 2 (7), which becomes the drive force
for slewing. ��������

3-23
 3
FUNCTION
SWIVEL JOINT

SWIVEL JOINT �
�
The swivel joint is mounted in the center of the machine’s
�
slew axis. It serves the role of maintaining continuous con-
nections in the hydraulic circuit, regardless of the upper
frame slew angle. �
The ports (3) are fitted on the hub (1) and the shaft (2).
�
These hub and shaft can be turned separately. The num-
ber of ports is the number of the fluid circuits. There are �
grooves formed in the inner circumference surface of the
hub (1) and the outer circumference surface of the shaft (2).
The seals (4) are fitted above and below these circumfer-
ential grooves. The oil flown from the port (3) continuously ��������

flows through the hydraulic passage (5) between the hub

(1) and the shaft (2), making the circuit always open without
being blocked even when the upper structure is slewing.

3-24
DISASSEMBLY AND ASSEMBLY 4
Service standards ........................................................ 4-2
Drive system ................................................................ 4-5
Travel system............................................................. 4-14
Slew system .............................................................. 4-19
Upper frame .............................................................. 4-22
Control system .......................................................... 4-28
Attachments .............................................................. 4-39
Hydraulic tank ........................................................... 4-45
Hydraulic pump ......................................................... 4-50
Control valve.............................................................. 4-74
Pilot valve .................................................................. 4-86
Proportional control solenoid valve............................. 4-93
Pilot valve (auxiliary) ................................................... 4-95
Pilot valve (travel) ..................................................... 4-106
Solenoid valve (1-section) ........................................ 4-121
Solenoid valve (2-section) ........................................ 4-124
Cylinders ................................................................. 4-127
Travel motor ............................................................ 4-144
Slew motor .............................................................. 4-159
Swivel joint .............................................................. 4-178
Air conditioner ......................................................... 4-183

4-1
 4
DISASSEMBLY AND ASSEMBLY
SERVICE STANDARDS

SERVICE STANDARDS
Carrier roller
Criteria (mm)
Code
Standard dimension Allowable value
A 84 80
� �
B 30 ––

��������

Track roller
Criteria (mm)
Code
Standard dimension Allowable value
A 110 106
B 35 ––

� �

��������

Drive sproket �
Criteria (mm)
Code
Standard dimension Allowable value
A 380.4 372
B 32 28

��������

Idler
Criteria (mm)
Code
Standard dimension Allowable value
A 350 344
B 45 ––
� �

��������

4-2
 4
DISASSEMBLY AND ASSEMBLY
SERVICE STANDARDS

Clearance for pin and bushing

4-3
 4
DISASSEMBLY AND ASSEMBLY
SERVICE STANDARDS

Unit: mm
Code Item Criteria Action
Standard Tolerance Standard Allowable
dimension Axis Hole clearance clearance
A Bucket and arm
-0.02 +0.025
45 0.045 to 0.170 1.0
-0.05 +0.120
-0.02 +0.025
B Bucket and link 45 0.045 to 0.170 1.0
-0.05 +0.120
-0.02 +0.025
C Arm and link 45 0.045 to 0.170 1.0
-0.05 +0.120
Link side
+0.025 0.045 to 0.170 1.0
-0.02 +0.120
D Bucket cylinder and link 45
-0.05 Cylinder side
+0.10 0.02 to 0.15 1.0
0
-0.02 +0.10
E Bucket cylinder and arm 45 0.02 to 0.15 1.0
-0.05 0
-0.02 +0.023
F Arm and boom 50 0.043 to 0.169 1.0
-0.05 +0.119
-0.02 +0.25
G Arm cylinder and arm 50 0.07 to 0.30 1.0
-0.05 +0.05
-0.02 +0.25
H Arm cylinder and boom 50 0.07 to 0.30 1.0
-0.05 +0.05 Replace
-0.02 +0.001
I Boom and swing bracket 60 0.021 to 0.109 1.0
-0.05 +0.059
-0.02 +0.25
J Boom cylinder and boom 60 0.07 to 0.30 1.0
-0.05 +0.05
-0.02 +0.25
K Boom cylinder and swing bracket 60 0.07 to 0.30 1.0
-0.05 +0.05
-0.02 0
L Swing bracket and turntable 105 0.020 to 0.123 1.0
-0.05 +0.073
-0.02 +0.20
M Swing cylinder and swing bracket 45 0.07 to 0.25 1.0
-0.05 +0.05
-0.02 +0.20
N Swing cylinder and turntable 45 0.07 to 0.25 1.0
-0.05 +0.05
-0.02 +0.12
O Blade cylinder and blade 55 0.02 to 0.17 1.0
-0.05 0
-0.02 +0.12
P Blade cylinder and lower frame 55 0.02 to 0.17 1.0
-0.05 0
-0.02 +0.025
Q Blade and lower frame 45 0.45 to 0.170 1.0
-0.05 +0.120
-0.02 0
R Swing bracket and turntable 105 0.020 to 0.123 1.0
-0.05 +0.073

4-4
 4
DISASSEMBLY AND ASSEMBLY
DRIVE SYSTEM

DRIVE SYSTEM
Removing the engine

�
�
��

��
� �
�

�
�
�
�
� �
�

�� �
�
�
��
�

� �
�
�

��

��

��������

B: With the marker “B”

C: With the marker “C”

1. Engine foot FR 8. Cushion rubber

2. Engine foot FL 9. Cushion rubber
3. Engine foot RR 10. Tail pipe
4. Engine foot RL 11. Ground cable
5. Air hose 12. Stopper
6. Air hose 13. Exhaust pipe (Canopy type)
7. Air hose 14. Air cleaner

4-5
 4
DISASSEMBLY AND ASSEMBLY
DRIVE SYSTEM

1. Disconnect the battery ground cable from the battery

terminal.

2. Remove the canopy.

“Removing the canopy”

3. Remove the floor frame.

“Removing the floor frame”

4. Disconnect the electrical wiring to the air cleaner (14).

5. Remove the air cleaner (14).

6. Remove the radiator.

“Removing the radiator”

7. Remove the drain hose.

“Removing the radiator”

8. Remove the hydraulic pump.

“Removing the hydraulic pump”

9. Disconnect the fuel hoses.

“Removing the fuel tank”

10. Disconnect the battery cable and the electrical wirings

from the engine side.
• Attach an identification label to each wiring.

11. Disconnect the engine ground cable (11).

12. Disconnect the accelerator wire from the engine, and

remove it together with the bracket.
“Adjusting the engine throttle lever”

13. Take out the bolts and remove the cushion rubbers (8)
and (9).
Bolt: ThreeBond #1324
Bolt: 102 N·m

14. Suspend the engine.

: 170 kg

Installing the engine

For installation of the engine, follow the same procedure as
for removal in the reverse order.

4-6
 4
DISASSEMBLY AND ASSEMBLY
DRIVE SYSTEM

Removing the radiator and oil cooler

�

��
��
� �
� �
�
� �
� �

�
�

�
�
� �
�
��

��
��
���������

��
��

��

��

��
��������

1. Bracket 11. Drain valve

2. Fan guard 12. Hose
3. Shroud 13. Hose
4. Plate 14. Hose
5. Cushion rubber 15. Plate
6. Cushion rubber 16. Plate
7. Radiator and oil cooler 17. Plate
8. Radiator hose (upper) 18. Plate
9. Radiator hose (lower) 19. Plate
10. Sub-tank

4-7
 4
DISASSEMBLY AND ASSEMBLY
DRIVE SYSTEM

1. Loosen the radiator cap to let engine coolant drain

from the drain valve (11).
• Engine coolant volume: 12.4 L

2. Disconnect the drain hoses (12) and (13).

3. Disconnect the radiator hoses (8) and (9) and the

hose.

4. Remove the fan guard (2).

5. Remove the nut fixing the cushion rubber.

6. Lift the radiator assembly (7) together with the radiator

bracket and remove it.
• Lift it slowly, sliding it out forward so that the shroud
does not come in contact with the cooling fan.

7. Disconnect the oil cooler hoses.

• Prepare a plate to catch any hydraulic oil coming out
of the hose.

8. Remove the radiator assembly (7).

: 25 kg

Installing the radiator and oil cooler

For installation of the radiator, follow the same procedure
as for removal in the reverse order.
The radiator should be mounted to be at right angles to the
frame and parallel to the cooling fan.

4-8
 4
DISASSEMBLY AND ASSEMBLY
DRIVE SYSTEM

Removing the hydraulic pump

�
�

��������

Apply molybdenum disulfide grease to the spline

1. Engine housing
2. Hydraulic pump
3. Coupling
4. Air-bleeding plug
5. Solenoid valve

4-9
 4
DISASSEMBLY AND ASSEMBLY
DRIVE SYSTEM

1. Remove the canopy or the cab.

“Removing the cab”

2. Remove the engine hood and the engine cover.

“Removing the covers”

3. Drain the oil from the hydraulic oil tank.

“Removing the hydraulic tank”

4. Disconnect the electrical wires from the solenoid valve

(5).

5. Disconnect the suction hoses from the hydraulic

pump.

6. Disconnect the discharge hoses from the hydraulic

pump.

7. Disconnect the hoses from the solenoid valve.

8. Remove the fixing bolts, and then remove the hydraulic

pump (2).
Apply molybdenum disulfide grease to the spline
Bolt: 102 N·m

Installing the hydraulic pump

For installation of the hydraulic pump, follow the same pro-
cedure as for removal in the reverse order.

Cautions on starting the hydraulic pump

1. Fill the pump housing with hydraulic oil before starting.
• Loosen the air-bleeding plug (4), and tighten it again
when oil starts to flow out from the hole.

2. After starting, let the engine run in low idle for a while to
bleed all air from the circuit.

4-10
 4
DISASSEMBLY AND ASSEMBLY
DRIVE SYSTEM

Removing the fuel tank

�
��

��
� �
�
��
��

� � �
�

��

��������

1. Fuel tank 8. Fuel hose

2. Flange 9. Fuel hose
3. Fuel sender 10. Fuel hose
4. Cover 11. Fuel hose
5. Drain valve 12. Feed pump
6. Band 13. Float
7. Band 14. Plate

4-11
 4
DISASSEMBLY AND ASSEMBLY
DRIVE SYSTEM

1. Remove the canopy or the cab.

“Removing the cab”

2. Remove the covers around the tank.

“Removing the covers”

3. Loosen the drain valve (5) to drain the fuel.

• Fuel tank capacity: 73 L

4. Disconnect the electrical wiring from the fuel sender

(3).

5. Disconnect the fuel hoses (8) and (11).

6. Take out the bolts and remove the plate (14).

7. Take out the nuts and remove the bands (7) and (6)
from the tank.

8. Remove the fuel tank (1).

Installing the fuel tank

For installation of the fuel tank, follow the same procedure
as for removal in the reverse order.

4-12
 4
DISASSEMBLY AND ASSEMBLY
DRIVE SYSTEM

Adjusting the throttle lever

Engine revolution �
1. Fasten the wire (2) to the throttle lever (1) with the wire
�
lock pin (3).

2. Move the throttle lever (1) to the “A” (low idle) position
and the governor (4) to the “C” position (idle).
• Make sure that the throttle lever (1) hits against the
� �
stopper (5). �

3. Fasten the wire (2) with the wire lock pin (6).
� �
� ��������

4. Move the throttle lever (1) to the “B” (full throttle) side
B
and set the governor (4) to the “D” (full throttle) posi-
tion. 1
• Adjust the stopper (7) so that the throttle lever (1)
hits against the stopper (7), and secure the stopper
with the lock nut (8).

D
4

8
7 ��������

Control force 1
1. Loosen the lock nut (9) and turn the nut (10) to adjust
the control force.
Control force 29.4 N
“2. Service data, Performance criteria, Lever oper-
9
ating force”

2. Upon completion of the adjustment, tighten the lock

nut (9) by holding the nut (10) to prevent it from turn-
ing.

3. Operate the throttle lever (1) again to make sure that

10
the control force is stable. 4BAA19Z

4-13
 4
DISASSEMBLY AND ASSEMBLY
TRAVEL SYSTEM

TRAVEL SYSTEM �

Removing the crawler belt

1. Loosen the tension of the crawler (1).
�
• When loosening the check valve (2), do it slowly.
When grease comes out, stop loosening it. If no
grease comes out, slightly move the machine for-
�
ward and backward.
Check valve: 177 N·m

��������

2. Fit the iron pipe (3) in the crawler, and then rotate the
sprocket in the reverse direction.

3. When the pipe reaches the side of the idler, stop the
rotation of the sprocket.

4. Slide the crawler to the side and remove it.

Crawler belt: 219 kg

4CAA02Z

Installing the crawler belt

1. Raise the machine and place the crawler on the
frame.
• Set the crawler so that it is engaged with the sprock-
et.

2. Fit the iron pipe (3) in the crawler, and then rotate the
sprocket in the reverse direction.

3. When the pipe (3) reaches the side of the sprocket,

stop the rotation of the sprocket. 3

4. Slide the crawler to a position where it can be properly 4CAA03Z

fitted with the idler.

5. Securely engage the crawler with the sprocket and the

idler, and then adjust the crawler tension.
“2. Service data, Performance criteria”

4-14
 4
DISASSEMBLY AND ASSEMBLY
TRAVEL SYSTEM

Removing the steel crawler

1. Stop the machine so that the master pin comes to the
front of the idler.

2. Relax the tension of the crawler (1).

When loosening the check valve (2), do it slowly and
stop as soon as grease start coming out. �
If no grease comes out, shake the machine a little.
Check valve: 177 N·m

3. Pull out the master pin (3) and detach the crawler (1). �

4. Raise the machine by using the dozer blade and the � ��������

hoe attachment, and then gradually remove the crawl-

er (1) while running the travel motor slowly in reverse.
Crawler 259 kg

��������

Installing the steel crawler

1. If using the blade and hoe attachment, raise the ma-
chine and position the crawler under the frame.
• Be careful to install the crawler in the proper direc-
tion.

2. Engage the links in the sprockets, and then slowly run

the travel motor in forward to wrap on the crawler.

3. Lower the machine, then install the master pin and en-
gage the crawler.
• After lining up the pin hole, first insert a temporary
pin. ��������

4. Raise the machine and adjust the crawler tension.

“2. Service data, Performance criteria”

��������

4-15
 4
DISASSEMBLY AND ASSEMBLY
TRAVEL SYSTEM

Removing the Carrier Roller

1. Relax the crawler belt tension.

2. Using a hydraulic jack, push up the crawler belt.

3. Loosen the fixing nut (3) to remove the bolt, and then
remove the roller (4).

� ��������

Installing the carrier roller

For installation of the carrier roller, follow the same proce-
dure as for removal in the reverse order.
Bolt: ThreeBond #1324
Bolt: 256 N·m

Removing the track roller

1. Loosen the tension of the crawler.

2. Slightly loosen the roller fixing bolt (1) (about one turn).
�
3. Raise the machine, remove the fixing bolt (1) and re- �
move the roller (2).

��������

Installing the track roller

1. Temporarily tighten the fixing bolt (1) on the roller (2).

2. Lower the machine to the ground and further tighten

the bolt.
Bolt: ThreeBond #1324
Bolt: 102 N·m

3. Raise the machine and adjust the crawler tension.

4-16
 4
DISASSEMBLY AND ASSEMBLY
TRAVEL SYSTEM

Exchanging between rubber crawlers and

steel crawlers
Required parts
Item Part No. Name Quantity
1 03913-00400 Spacer 20
2 11010-51255 Bolt 40
3 04610-00700 Guide 4
4 11010-41230 Bolt 12
5 11400-20012 Washer 12

WARNING
If you must work beneath the raised machine or equip-
ment, always use wood blocks, jack stands or other
rigid and stable supports. Never get under the machine
or working equipment if they are not sufficiently sup-
ported.

Refer to the previous page for removing and installing the

crawler belt.
1. Remove the track roller.
“Removing the track roller” �

2. Insert the spacer (1) between the carrier roller bracket

and the frame, and then install the track roller.
“Installing the track roller”

3. Install the guide (3) on the idler side of the frame and
secure the guide (3) using the washer (5) and the bolt
�
(4).
“Installing the track roller” ��������

3
4
4C0AH02Z

4-17
 4
DISASSEMBLY AND ASSEMBLY
TRAVEL SYSTEM

Removing the idler and the track adjuster

1. Remove the crawler.
“Removing the crawler belt”

2. Pull out the idler and the track adjuster.

Idler + track adjuster: 67 kg

��������

Installing the idler and the track adjuster

For installation of the idler and the track adjuster, follow the
same procedure as for removal in the reverse order.
The sliding surfaces of the track adjuster piston and
the cylinder

Removing the travel motor � �

1. Remove the crawler.
“Removing the crawler belt”

2. Take out the fixing bolts (1) and remove the sprocket
(2).
Bolt: ThreeBond #1324
Bolt: 156 N·m

3. Take out the cover and disconnect the hydraulic hoses

(4).
�
4. Suspend the travel motor (3) temporarily and remove ��������

the fixing bolts (5).

Bolt: ThreeBond #1324
Bolt: 156 N·m �

5. Raise the travel motor (3) and remove it.

Travel motor: 57 kg

�
� ��������

Installing the travel motor

For installation of the travel motor, follow the same proce-
dure as for removal in the reverse order.

4-18
 4
DISASSEMBLY AND ASSEMBLY
SLEW SYSTEM

SLEW SYSTEM
Removing the slew motor
�

1. Slew motor
��������

1. Tilt up the floor frame.

2. Disconnect the hydraulic hoses from the slew motor

(1).

3. Remove the bolts fixing the slew motor.

Bolt: ThreeBond #1324
Bolt: 256 N·m

4. Suspend the slew motor (1), and then remove it.

Slew motor: 50 kg

Installing the slew motor

For installation of the slew motor, follow the same proce-
dure as for removal in the reverse order.

4-19
 4
DISASSEMBLY AND ASSEMBLY
SLEW SYSTEM

Removing the slew bearing

1. Slew bearing
��������

1. Remove the hoe attachment.

“Removing the hoe attachment”

2. Remove the upper frame.

3. Remove the inner race fixing bolts.

Bolt: ThreeBond #1324
Bolt: 256 N·m

4. Suspend the slew bearing and remove it.

Slew bearing: 84 kg

Installing the slew bearing

For installation of the slew bearing, follow the same proce-
dure as for removal in the reverse order.
• When installing the slew bearing on the upper frame, be
sure to position the reamer bolts and the grease holes
as shown in the figure.
• Apply grease to the inner teeth of the slew bearing.

��������

4-20
 4
DISASSEMBLY AND ASSEMBLY
SLEW SYSTEM

Removing the swivel joint

1. Swivel joint
2. Stopper
��������

1. Remove the upper frame.

“Removing the upper frame”

2. Disconnect the hydraulic hoses from the hub side of

the swivel joint (1).

3. Remove the swivel joint fixing bolts.

Bolt: ThreeBond #1324
Bolt: 102 N·m

4. Suspend the swivel joint (1) and remove it.

Installing the swivel joint

For installation of the swivel joint, follow the same proce-
dure as for removal in the reverse order.
• When installing the swivel joint, tighten it temporarily
with the fixing bolts, and then center the swivel joint by
using a dial gauge.
• Adjust the centering so that the deviation from the cen-
ter is within 0.25 mm.

4-21
 4
DISASSEMBLY AND ASSEMBLY
UPPER FRAME

UPPER FRAME
Removing the upper frame

1. Upper frame
� 2. Counterweight
��������

3. Grease pipe
��������

4-22
 4
DISASSEMBLY AND ASSEMBLY
UPPER FRAME

1. Remove the hoe attachment.

“Removing the hoe attachment”

2. Remove the canopy or the cab.

3. Remove the covers.

“Removing the covers”

4. Disconnect the hydraulic hoses from the swivel joint.

5. Remove the fixing bolts and then the stopper.

“Removing the swivel joint”
Bolt: 102 N·m

6. Disconnect the grease pipe (3) from the slew bearing.

7. Remove the fixing bolts from the outer race of the slew
bearing, leaving only two bolts each on the front and
the rear of the machine.
• When installing the slew bearing, be careful to align
it with the positions of the grease hole and reamer
bolts.
“Removing the slew bearing”
Bolt: ThreeBond #1324
Bolt: 102 N·m

8. Suspend the upper frame temporarily and remove the

remaining fixing bolts while keeping the frame well bal-
anced.

9. Suspend the upper frame and remove it.

Installing the upper frame

For installation of the upper frame, follow the same proce-
dure as for removal in the reverse order.

4-23
 4
DISASSEMBLY AND ASSEMBLY
UPPER FRAME

Removing the covers

1/2

�
�

��

�
�

�
��

��
��
� �

��

�
��

��������

1. Engine hood 8. Hinge

2. Front cover 9. Plate
3. Side cover R 10. Cover
4. Side cover L 11. Bracket
5. Tank cover 12. Stay damper
6. Front cover 13. Stay damper
7. Center cover 14. Rod

4-24
 4
DISASSEMBLY AND ASSEMBLY
UPPER FRAME

2/2

��

��

��
��

� ��
��

��������

15. Side frame R

16. Side frame L
17. Tool box
18. Cover
19. Bracket
20. Cover

4-25
 4
DISASSEMBLY AND ASSEMBLY
UPPER FRAME

1. Disconnect the battery ground cable from the battery

terminal.

2. Remove the engine hood (1).

a. Open the engine hood and suspend it temporarily.
b. Disconnect the electric wiring of the taillight.
c. Remove the stay damper (13).

3. Remove the center cover (7).

4. Remove the side covers R (3) and L (4).

5. Remove the fixing bolts. Remove the rod (14), discon-

nect the light wiring and detach the front cover (6).

6. Remove the tool box (17).

7. Remove the side frames R (15) and L (16).

8. Remove the undercover (18).

Installing the covers

For installation of the covers, follow the same procedure as
for removal in the reverse order.
• When assembling, be sure to leave a 2 mm clearance ���
between the stay damper and the stay damper fixing
bolt.

��� ��������

4-26
 4
DISASSEMBLY AND ASSEMBLY
UPPER FRAME

Removing the cab

1. Cab assembly
��������

1. Disconnect the battery ground cable from the battery

terminal.

2. Disconnect the electric wiring from the cab.

3. Remove the fixing bolts.

4. Suspend the cab and remove it.

Cab: 240 kg

Installing the cab

For installation of the cab, follow the same procedure as for
removal in the reverse order.
• Suspend the cab in a horizontal position. Fasten the fix-
ing bolts temporarily while the cab is suspended.

4-27
 4
DISASSEMBLY AND ASSEMBLY
CONTROL SYSTEM

CONTROL SYSTEM
Removing the lever stand
Control lever

�
�
�

� �

�
�

�
�

��������

1. Pedal assembly L
2. Pedal assembly R
3. Lever L
4. Lever R
5. Pilot valve (1st auxiliary)
6. Pedal assembly (swing)
7. Control cable
8. Pilot valve (travel)

4-28
 4
DISASSEMBLY AND ASSEMBLY
CONTROL SYSTEM

Control lever pedal (Aux. 1 proportional control)

� �
�

�
�
�

��������

1. Pedal assembly L
2. Pedal assembly R
3. Lever L
4. Lever R
5. Proportional control valve
6. Pedal assembly (swing)
7. Control cable
8. Pilot valve (travel)

4-29
 4
DISASSEMBLY AND ASSEMBLY
CONTROL SYSTEM

Control lever pedal (1st auxiliary ON/OFF)

� �
� �

�
�
� �
� �

�
����

����

�
����
�

� �
���� �

����
����

��������

1. Pedal assembly L
2. Pedal assembly R
3. Lever L
4. Lever R
5. Pilot valve (1st auxiliary)
6. Pedal assembly (swing)
7. Control cable
8. Pilot valve (travel)
9. Solenoid valve (ON/OFF)

4-30
 4
DISASSEMBLY AND ASSEMBLY
CONTROL SYSTEM

Hydraulic pilot unit

A type (ISO)
��
�� �� �� ��
��
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�
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��� �
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����
����

���� ��������

Table of connection
1 R1 ↔ pb1 4 1. Right pilot valve
1 R2 ↔ pa2 4 2. Left pilot valve
1 R3 ↔ pa1 4 3. Pilot valve (travel)
1 R4 ↔ pb2 4 4. Control valve
1 RP ↔ TRP 3 5. Pilot valve
1 RT ↔ TRT 3 6. Shuttle valve
2 L1 ↔ SHAA 6 7. Hydraulic tank
2 L2 ↔ pb7 4
2 L3 ↔ pb8 4
2 L4 ↔ SHAB 6
2 LP ↔ 1SSP 5
2 LT ↔ 1SST 5
3 TR1 ↔ pa4 4
3 TR2 ↔ pb4 4
3 TR3 ↔ pa3 4
3 TR4 ↔ pb3 4
3 TRP ↔ 1SSP 5
3 TRT ↔ 1SST 5
3 TRT ↔ T1 7
5 L ↔ pb6 4
5 R ↔ pa6 4
6 SHAA ↔ pa8 4
6 SHAB ↔ pa7 4

4-31
 4
DISASSEMBLY AND ASSEMBLY
CONTROL SYSTEM

A type(ISO) ↔G type(JCB)
��
�� ��
�� ��
��
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�
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�� ��
�� �� ��
��
��
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�� �

���
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���
��� �� ��
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��� �� ��
���
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��� ��
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��� � ��
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���
��� ��� ���
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���� � �
����

���� � ��������

Table of connection
1 R1 ↔ pb1 4 1. Right pilot valve
1 R2 ↔ 1 8 2. Left pilot valve
1 R3 ↔ pa1 4 3. Pilot valve (travel)
1 R4 ↔ 2 8 4. Control valve
1 RP ↔ TRP 3 5. Pilot valve
1 RT ↔ TRT 3 6. Shuttle valve
2 L1 ↔ SHAA 6 7. Hydraulic tank
2 L2 ↔ 3 8 8. Selector valve
2 L3 ↔ pb8 4
2 L4 ↔ 4 8
2 LP ↔ 1SSP 5
2 LT ↔ 1SST 5
3 TR1 ↔ pa4 4
3 TR2 ↔ pb4 4
3 TR3 ↔ pa3 4
3 TR4 ↔ pb3 4
3 TRP ↔ 1SSP 5
3 TRT ↔ 1SST 5
3 TRT ↔ T2 7
5 L ↔ pb6 4
5 R ↔ pa6 4
6 SHAA ↔ pa8 4
6 SHAB ↔ pa7 4
8 A ↔ pa2 4
8 B ↔ pb2 4
8 C ↔ pb7 4
8 D ↔ SHAB 6

4-32
 4
DISASSEMBLY AND ASSEMBLY
CONTROL SYSTEM

Blade lever

�
�

��������

When assembling, be sure to apply NEVER SEEZ

(anti-seize and lubricating agent) to the inner surfaces
of the DU bush.
1. Base plate
2. Lever
3. Control cable
4. Yoke

4-33
 4
DISASSEMBLY AND ASSEMBLY
CONTROL SYSTEM

Lever stand

� �

��
�

� �

��������

1. Bracket
2. Lever
3. Lever
4. Bracket
5. Control box
6. Plate
7. Pilot valve
8. Limit switch
9. Stay damper
10. Pin

4-34
 4
DISASSEMBLY AND ASSEMBLY
CONTROL SYSTEM

Control box R (Cab)

�
�

�
�� �
�
�

�
1. Cover R
2. Plate
3. Cover
� 4. Starter switch
�
5. Light switch
6. Cluster gauge
�� � 7. Valve
� � 8. Hour meter
9. Heater switch
10. Wiper switch
��������
11. Wiper relay
A: With air conditioner

Control box R (Canopy)

�
�

�
�

1. Cover R
2. Cover
3. Starter switch
� 4. Light switch
5. Cluster gauge
6. Valve
��������
7. Hour meter

4-35
 4
DISASSEMBLY AND ASSEMBLY
CONTROL SYSTEM

Control box L

�
�
�
� �

� �
�
�
�
�

1. Cover L
�
2. Cover L
3. Ornament
4. Ornament
��������
5. Cover L
A: Emergency shut-off valve
B: Emergency shut-off valve, arm holding limit

Control box L (with air conditioner and heater for cold climates)

� �
�
�
� �

�
�
�
�
1. Cover L
�
2. Air conditioner/blower (fan)
� switch
3. Attenuator (thermal)
4. Cover L
5. Cover L
6. Cover L
7. Ornament
� ��������
8. Ornament
A: Emergency shut-off valve
B: Emergency shut-off valve, arm holding limit

4-36
 4
DISASSEMBLY AND ASSEMBLY
CONTROL SYSTEM

1. Disconnect the battery ground cable from the battery

terminal.

2. Remove the cab.

“Removing the cab”

3. Remove the lever stand L.

a. Remove the cover (upper) of control box L.
b. Pull up the lock lever and lift up the lever stand.
Then, pull out the pin and remove the lock lever.
c. Disconnect the hydraulic hoses from the pilot valve.
• Attach an identification label to each hydraulic
hose for easy reassembly.
d. Disconnect the electrical wiring of the limit switch.
e. Take out the stay damper and the pin, and then re-
move the control box.

4. Remove the lever stand R.

a. Remove the cover (upper) of control box R.
b. Remove the cover (lower) of control box R.
c. Disconnect the electric wires.
d. Disconnect the hoses from the pilot valve.
• Attach an identification label to each hydraulic
hose for easy reassembly.

Installing the lever stand

For installation of the lever stand, follow the same proce-
dure as for removal in the reverse order.

4-37
 4
DISASSEMBLY AND ASSEMBLY
CONTROL SYSTEM

Adjusting the control cable

Adjust the lever stroke length by using the setscrew so that
it is long enough for the spool stroke on the control valve.
1. The control valve (1) spool should be in the neutral po-
sition. � �
�
2. Turn the nut (2) and position the lever (3) in the center
of the stroke, and then fasten the control cable (4) with
the nut. � � � �

3. Move the lever (3) and hold it at the stroke end of the
�
valve spool.

4. Install the setscrew (6).

��������

4-38
 4
DISASSEMBLY AND ASSEMBLY
ATTACHMENTS

ATTACHMENTS
Removing the attachments

��

�
�

��

� � ��
��
��������

1. Bucket 8. Boom
2. Bucket link 9. Boom cylinder
3. Guide link R 10. Swing bracket
4. Guide link L 11. Swing cylinder
5. Bucket cylinder 12. Blade cylinder
6. Arm 13. Dozer blade
7. Arm cylinder

4-39
 4
DISASSEMBLY AND ASSEMBLY
ATTACHMENTS

WARNING
• Be sure to release the residual pressure from the hy-
draulic hose before disconnecting it.
• When adjusting the pin hole position, never put your
finger into the hole.

Important:
• When tightening the lock bolt with a double nut, al-
low a clearance of 0.5 to 1.0 mm between the nut
and the lock collar.
• When assembling, adjust the pin-connecting area
with a shim so that no clearance is left. Be sure to
reduce the clearance until a 0.2-mm-thick-shim can-
not be inserted by hand.
• Be sure to bleed the air from the cylinder before
starting for the first time after reassembling hydrau-
lic devices such as the hydraulic cylinder or hydrau-
lic piping.
0.5~1.0mm

4GAA01Z

Removing the bucket

• Lower the bucket so that its back side surface rests on �
the ground.
1. Take out the lock bolt (1) and remove the pin (2).
� �
2. Take out the lock bolt (1) and remove the pin (3).

�
3. Remove the bucket.
Bucket: 108 kg

��������

Installing the bucket � �

For installation of the bucket, follow the same procedure as
for removal in the reverse order.
• Before mounting the bucket, position the O-ring provi-
sionally at the “A” position on the outer perimeter of the
bucket bushing, and after completion, move it to the
prescribed position “B”.

��������

4-40
 4
DISASSEMBLY AND ASSEMBLY
ATTACHMENTS

Removing the link �

Fully retract the bucket cylinder and lower the front end of
the arm to the ground.
1. Pull out the cotter pin and remove the castle nut (1). �

2. Suspend the bucket link (2) temporarily and remove

the pin (3).
• Place the bucket link on a skid.
• Be aware that one end of the guide link will fall down
�
when the pin (3) is pulled out.
�
3. Pull out the pin (4), and then remove the guide links L �
(5) and R (6). � ��������

Installing the link

For installation of the link, follow the same procedure as for
removal in the reverse order.

�
Removing the arm
1. Disconnect the hydraulic hoses (1) from the bucket cyl-
�
inder (2).
Next, disconnect the hydraulic hoses from the auxiliary
ports (3).

2. Suspend the bucket cylinder (1) temporarily, pull out �

the pin (4) and then remove the bucket cylinder
Bucket cylinder 32 kg

3. Place the arm cylinder on a skid and pull out the pin �
(6). ��������

4. Pull out the cotter pin and remove the castle nut (7).
�
5. Suspend the arm (8) temporarily, pull out the pin (9)
and then remove the arm.
Arm: 91 kg
�

Installing the arm

�
For installation of the arm, follow the same procedure as for
removal in the reverse order.
Important:
When securing the arm with the fixing pin (9) and the �
castle nut (7), be sure not to overtighten the castle nut
(7). � ��������

Temporarily tighten the castle nut (7) by hand, adjust

the position so that the hole on the castle nut (7) aligns
with the fixing pin (9), and then secure the nut with a
cotter pin.

4-41
 4
DISASSEMBLY AND ASSEMBLY
ATTACHMENTS

Removing the boom

Lower the front end of the boom fully to the ground. �
1. Disconnect the hydraulic hoses (1) from the arm cylin-
der (2).

2. Suspend the arm cylinder (2) temporarily, pull out the

pin (3) and then remove the arm cylinder.
Arm cylinder: 33 kg �
�
3. Take out the clamp from the boom (4), and then dis-
connect the hydraulic hoses (5) from the boom cylinder
(6).
��������

4. Suspend the boom cylinder (6) temporarily and remove

the pin (7).
• Lower the boom so that the side where the cylinder
rod was removed touches the ground. �

5. Disconnect the boom light wiring.

6. Disconnect the hydraulic hoses (8) from the pipe.

�
�
7. Suspend the boom (4) temporarily, pull out the pin (9)
and then remove the boom. �
Boom: 192 kg

�
Installing the boom � ��������

For installation of the boom, follow the same procedure as

for removal in the reverse order.

4-42
 4
DISASSEMBLY AND ASSEMBLY
ATTACHMENTS

Removing the swing bracket

1. Suspend the boom cylinder (1) temporarily, pull out the �
� �
pin (2) and then remove the boom cylinder.
Boom cylinder: 58 kg

2. Remove the blade (3) from the swing bracket (4). � �

3. Pull out the pin (5) and remove the swing cylinder (6)
from the swing bracket (4).
� �
4. Suspend the swing bracket (4) temporarily, pull out the
�
pins (7) and (8), and then remove the swing bracket.
• Be careful not to damage the hoses. ��������

Swing bracket: 135 kg

Installing the swing bracket

For installation of the swing bracket, follow the same pro-
cedure as for removal in the reverse order.
• When assembling, be sure to apply NEVER SEEZ (anti-
seize and lubricating agent) to the pin holes for installing
the swing bracket, and then install the pins (8) and (7).

4-43
 4
DISASSEMBLY AND ASSEMBLY
ATTACHMENTS

Removing the dozer blade �

Lower the dozer blade fully to the ground.

�
1. Disconnect the hydraulic hoses (1) from the blade cyl-
inder (2).

2. Suspend the blade cylinder (2) temporarily, pull out the �

pins (3) and (4), and then remove the blade cylinder
�
(2).
Blade cylinder: 41 kg �

3. Suspend the blade (5) temporarily, pull out the pin (6)
and then remove the blade (5). ��������

Blade: 201 kg

� ��������

4-44
 4
DISASSEMBLY AND ASSEMBLY
HYDRAULIC TANK

HYDRAULIC TANK
Removing the hydraulic tank

��

� ��
��

�� ��
�� ��
�� ��
� ��

� �� ��
�
�� ��
�
�
�
�
��
�
�
�� �
�
�
�

�� ��
��
�
�
��

��������

A : with air breather

1. Tank 11. Elbow 21. Suction filter

2. Pipe assembly 12. Elbow 22. Return filter
3. Pipe 13. O-ring 23. Adaptor
4. Pipe 14. Plate 24. Adaptor
5. O-ring 15. Hose 25. Sight gauge
6. Check valve 16. O-ring 26. Air breather
7. Pipe 17. Drain plug 27. Element
8. Elbow 18. Plug 28. O-ring
9. Check valve 19. Hose
10. Stop valve 20. Hose

4-45
 4
DISASSEMBLY AND ASSEMBLY
HYDRAULIC TANK

1. Remove the cab or the canopy.

“Removing the cab”

2. Remove the covers around the tank.

“Removing the covers”

3. Drain the hydraulic oil from the tank (1).

a. Gradually loosen the filler plug to release all internal
pressure beforehand.
b. Loosen the drain plug (6) and drain out the oil.
• Tank capacity: 52 L

4. Disconnect the low pressure hoses from the tank.

5. Disconnect the hydraulic hoses from the tank.

Attach an identification label to each hose for easy re-
assembly.

6. Remove the fixing bolts, suspend the tank and remove

it.
Bolt: ThreeBond #1324
Bolt: 47 N·m
Tank: 36 kg

Installing the hydraulic tank

For installation of the hydraulic tank, follow the same proce-
dure as for removal in the reverse order.

4-46
 4
DISASSEMBLY AND ASSEMBLY
HYDRAULIC TANK

Inspecting the hydraulic oil tank level and

refilling
WARNING
Oil may spurt out if caps or filters are removed or pipes
are disconnected before releasing the pressure in the
hydraulic system.
• Slowly loosen the air-bleeding plug to relieve the in-
ternal pressure of the hydraulic oil tank.
• Press the air breather button to relieve the tank pres-
sure (models with air breather).

Machine setup for inspecting the hydraulic oil level

1. Start the engine and run it at low speed.
�
2. Fully retract the arm cylinder and bucket cylinder and �
lower the bucket to the ground.
�
3. Stop the engine.

4. Inspect the oil level using the sight gauge (1).

At an oil temperature of about 20°C, the level in the
tank should be halfway between the upper limit (H) and
the lower limit (L). If it is below the lower limit (L), refill.
At an oil temperature of about 50 to 80°C, the level ��������

should be near the upper limit (H).

4-47
 4
DISASSEMBLY AND ASSEMBLY
HYDRAULIC TANK

Refilling
Important: Do not refill to above the (H) mark. This can
result in damage to the hydraulic circuit or cause oil to
spurt out. If accidentally filled to above the (H) mark,
stop the engine, and after allowing the hydraulic oil to
cool off, drain the excess oil from the drain plug.
Important: Failure to pressurize the hydraulic tank will
cause the pump to suck in air, which will adversely af-
fect the hydraulic units.
�
1. Open the fuel lid.

2. Slowly loosen the air-bleeding plug (2) to relieve the in-

ternal pressure, and then remove it.
<Models with air breather>
Open the side cover, press the button (3) to relieve the
internal pressure from the tank. �

3. Add hydraulic oil up to the middle of the sight gauge

(1).

4. Pressurize the hydraulic oil tank according to the fol- ��������

lowing procedure:
• The hydraulic tank of models with air breather does
not need to be pressurized.

Pressurizing the hydraulic tank

1. Start the engine and run it at low speed.

2. Remove the air-bleeding plug (2), and then place the

safety lock lever in the released position.
• Setup for pressurizing the hydraulic tank

3. Fully extend bucket, arm, boom and swing cylinders.

(Tank pressurizing setup)

4. Stop the engine and place the safety lock lever in the
locked position.
��������

5. Tighten the air-bleeding plug (2) and start to pressurize.

(Retract the cylinders to start pressurizing)

4-48
 4
DISASSEMBLY AND ASSEMBLY
HYDRAULIC TANK

Bleeding the air

After replacing the hydraulic oil, bleed the air from the hy-
draulic circuit and the hydraulic units. Failure to do so may
�
damage the hydraulic devices.

Hydraulic pump
1. Loosen the air-bleeding plug (1) of the hydraulic
pump.

2. Tighten the plug (1) once the hydraulic oil overflows

from the hole.

Cylinders ��������

1. Start the engine and let it run at a low-idling speed for

10 minutes.

2. While the engine runs at low-idle, extend and retract

each cylinder 4 or 5 times, without letting them reach
the stroke end.

3. While running the engine at high speed, extend and

retract each cylinder 4 or 5 times, without letting them
reach the stroke end.

4. Return the engine speed to low idle, then extend and

retract each cylinder 4 or 5 times up to the stroke
end.

4-49
 4
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP

HYDRAULIC PUMP
Construction

� � � �� � �� � �

� �

� � � ��

��������

1. Shaft 7. Gear pump

2. Swash plate 8. Housing
3. Cylinder block 9. Solenoid valve
4. Cover 10. Relief valve
5. Spring seat 11. Spring (outer)
6. Piston control 12. Spring (inner)

4-50
 4
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP

Special tools
Jig A

��������

Jig B

��������

Disassembly
1. Take out the cap screws and remove the solenoid valve
from the pump.
• Hold the pump upright with the shaft side on the
bottom and place the pump onto the jig A so that
the shaft end does not come in contact with the
working table surface.

��������

2. Take out the cap screws and remove the gear pump.

��������

4-51
 4
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP

3. Remove the coupling and the bushing.

��������

4. Take out the cap screw and remove the cover.

• When removing, keep the cover in a level position.
• Do not damage the valve plate fitted on the back.
• If it is hard to remove, lightly tap the cover with a
plastic hammer.

��������

5. Remove the two springs (inner and outer).

6. Remove the spring seat (1).

��������

7. Disassemble the cylinder block.

a. Remove the cylinder block from the shaft.

��������

4-52
 4
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP

b. Remove the plate from the shaft.

��������

c. Remove the guide (3), pins (5), retainer (5) and pis- � � �
tons (6) from the cylinder block (7).
• Do not disassemble the cylinder block (7) unless
necessary.

� � ��������

8. Take out the snap ring and remove the oil seal case (8)
and the O-ring. �
• When removing the oil seal case, use two flat head
screwdrivers as shown in the figure.

��������

9. Tap the shaft rear end with a plastic hammer and re-
move the shaft.

��������

4-53
 4
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP

10. Disassemble the swash plate section.

a. Take out the cap screw and remove the plate (9). ��
b. Remove the distance piece (10).
c. Remove the bearing (11). ��
�

��������

d. Remove the swash plate.

��������

11. Disassemble the cover section.

a. Remove the valve plate.

��������

b. Take out the cap screw and remove the piston con-
trol section (14).
• Do not disassemble the piston control section ��
(14) unless necessary.
• Loctite #270 has been applied on the cap
screw.

��������

4-54
 4
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP

c. Remove the pin (12) and the piston (13) from the
cylinder (14). ��
d. For the machine with an air conditioner, remove the ��
piston (15). (Only the machine with an air condition-
��
er)

��
��

��������

e. Remove the piston (16).

��

��������

f. Remove the three conical spring washers and the

spring seat.

��������

g. Take out the cap screws and remove the cover.

��������

4-55
 4
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP

h. Take out the spring seat and remove the O-ring from
the spring seat.

��������

12. Disassemble the shaft section.

a. Remove the snap ring.
b. Tap the shaft with a plastic hammer and remove the
shaft.

��������

13. Remove the relief valve.

• Do not assemble the relief valve unless necessary.
a. Remove the nut.
• Note down the free length of the setscrew before
disassembling.

��������

b. Remove the setscrew (17).

• Be careful not to drop the shim.
c. Remove the spring (18).
d. Remove the spool (19).

��

��

��

��������

4-56
 4
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP

14. Take out the cap screws and separate the assembly
into the hydraulic pump and the pumps P3 and P4.

��������

15. Disassemble the pump P4.

a. Pull up the drive gear and remove the seal ring, the
backup ring and the plate.

��������

b. Remove the driven gear.

��������

16. Disassemble the pump P3.

a. Take out the cap screws and remove the flange.
b. Remove the O-rings.

��������

4-57
 4
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP

c. Remove the frame.

��������

d. Remove the seal ring.

��������

e. Remove the plate, the guide and the O-rings.

��������

f. Remove the drive gear, the driven gear and the

bushing.

��������

4-58
 4
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP

17. Disassemble the solenoid valve.

a. Remove the filter and the O-rings.

��������

b. Remove the nut.

c. Remove the solenoid.

��������

d. Remove the base.

• Be careful not to drop the push rod.

��������

e. Remove the spool and the spring.

��������

4-59
 4
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP

f. Remove the plug.

��������

g. Remove the spring and the ball.

��������

4-60
 4
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP

Assembly
1. Assemble the swash plate section.
a. Install the swash plate on the housing.

��������

b. Install the bearing (11).

c. Install the distance piece (10). ��
d. Install the O-ring on the plate (9).
e. Install the plate (9) and secure it with cap screws. ��
Cap screw: 12 to 15 N·m �

��������

2. Assemble the shaft section.

a. Install the bearing on the shaft using the jig B.
• Use the bearing as a bed and press fit the shaft
using a press or a plastic hammer.
b. Install the snap ring and secure the bearing.
�

��������

3. Install the shaft on the housing.

• Lightly tap the spring tip with a plastic hammer and
make sure that the outer ring of the bearing is se-
curely fitted in the housing hole.

4. Install the O-ring.

��������

4-61
 4
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP

5. Install the oil seal case with the oil seal.

• When installing, keep the oil seal case straight.
• Apply grease on the oil seal lip.

6. Install the snap ring.

��������

7. Assemble the cylinder block.

a. Install the pins (4) on the cylinder block. �
• Apply grease on the pins (4) to prevent it from
dropping out.

��������

b. Install the guide (3) on the cylinder block. �

• Apply grease on the spherical part of the guide
c. Install the piston (6) on the retainer (5), and then in- �
stall the retainer (5) on the cylinder block.
�

��������

8. Install the plate on the swash plate.

• To prevent the plate from dropping out, apply grease
on the surface of the plate to be installed on the
swash plate.

� ��������

��������

4-62
 4
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP

9. Install the cylinder block by aligning it with the shaft

spline.
• Apply grease on the sliding surface of the piston
shoe and the sliding surface against the control
plate on the cylinder block.

��������

10. Install the spring seat (1).

• Apply grease on the spherical part of the spring
seat.

11. Install the two springs (inner and outer).

��������

12. Assemble the cover section.

a. Install the spring seat (18) and the conical spring
washers (17).
• Be sure to install the washers in the correct direc-
tion.
b. Install the piston (16).

��

��
��

�������� ��������

c. For a machine with an air conditioner, install the pis-

ton (15) (Only for the machines with air condition- ��
ers) ��
d. Install the O-rings on the cylinder (14).
��
e. Apply grease on the two pins (12) and the piston
(13), and then install them on the cylinder (14).

��
��

��������

4-63
 4
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP

f. Place the cylinder (14) in the specified position and

secure it using the cap screws.
Cap screw: 28 to 35 N·m ��
Apply Loctite #270.

��������

g. Fit the O-ring to the spring seat and install the spring
seat.

��������

h. Place the cover in the specified position and secure

it using the cap screws.
Cap screw: 28 to 35 N·m

��������

i. Apply grease on the back of the valve plate and in-

stall it on the cover by aligning the knock hole.
j. Install the O-rings (large and small) on the cover.

��������

4-64
 4
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP

13. Install the relief valve.

a. Install the spool (19).
b. Install the spring (18).
c. Fit the shim to the setscrew (17) and install it on the
cover.
��

��

��

��������

d. Install the nut.

• After assembly, set the pressure and secure the
valve.
Nut: 9.8 N·m

��������

14. Install the cover and secure it using the cap screws.
• When installing, keep the cover parallel to the hous-
ing surface the cover to be installed.
Cap screw: 98 to 123 N·m

��������

15. Install the O-ring and the bushing on the cover.

��������

4-65
 4
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP

16. Install the coupling on the shat end of the main pump.

��������

17. Assemble the pump P3.

a. Engage the bushing and install the square ring (20).
• Be sure to install it in the correct direction.
��

� � �
��������

A: Discharge side
B: Suction side
��������

b. Install the bushings that were set as above on both

sides of the drive gear and driven gear, and then
install them on the housing.

c. Fit the O-ring to the guide (18) and install it on the

plate (17).
• The O-ring on the guide should be installed on
the rounded corner of the plate’s circumference.

��

�� ��������

��������

4-66
 4
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP

d. Install the plate that was set as above on the hous-

ing.
• Be sure to install the plate in the correct direc-
tion.

� �

��������

A: Discharge side
B: Suction side ��������

e. Install the seal ring.

��������

18. Assemble the pump P4.

a. Install the drive gear on the housing.

��������

b. Install the driven gear on the housing.

��������

4-67
 4
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP

c. Install the seal ring (21) and the backup ring (22) on
the plate (23).
• Apply grease on the rings to prevent them from
dropping out.
��

��

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�� ��������

d. Install the plate on the housing.

��������

e. Install the two pins and O-ring on the frame.

��������

f. Install the frame on the housing.

��������

4-68
 4
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP

g. Secure the frame and housing using the cap

screws.
Cap screw: 28 to 35 N·m

��������

h. Fit the two pins to the frame and install the coupling
on the shaft end of the pump P3 side.

��������

19. Connect the pumps P3 and P4 and secure them using

the cap screws.
Cap screw: 55 to 69 N·m

��������

20. Install the O-ring on the frame.

��������

4-69
 4
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP

21. Assemble the solenoid valve.

a. Install the ball and the spring on the body.

��������

b. Install the plug.

Plug: 13.2 to 17.6 N·m

��������

c. Install the springs and the spools on the body.

��������

d. Install the bases.

Base: 30 to 37 N·m

��������

4-70
 4
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP

e. Secure the solenoids using the nuts.

Nut: 4.9 N·m

��������

f. Install the O-rings and the filter on the body.

��������

22. Connect the main pump and the gear pump and se-
cure them using the cap screws.
• Hold the pump upright with the shaft side on the
bottom and place the pump onto the jig A so that
the shaft end does not come in contact with the
working table surface.
Cap screw: 55 to 69 N·m

��������

23. Install the solenoid valve on the pump and secure the
valve using the cap screws.
Cap screw: 28 to 35 N·m

��������

4-71
 4
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP

Inspection and adjustment

Checking the parts
Part Criteria Action
Piston and cylinder A clearance (S) of 0.05 mm or more be- Replace
block assembly tween the piston and the cylinder block
assebly Replace

�
�
Occurrence of scratches, scoring, ab-
normal wear, etc. on sliding parts
�������
��������

Play of piston and A play S of 0.2 mm or more at the pis- Replace

shoe ton and shoe

��������

Shaft and oil seal A wear amount of 0.025 mm or more at Replace

�
mount the shaft and oil seal mount
e: Oil seal mount
f: Standard dimen-
�

sion

��������

Valve plate Abnormal scratches (0.02 mm or Repair by lapping or

more), wear, or scorching on the sliding replace
surfaces
Bushing Abnormal wear or harmful scratches on Replace
the sliding surfaces
Seals and O-rings At the time of reassembly after disas- Replace
sembly
Drive gears and driv- Abnormal scratches, wear or flaking of Replace
en gears the tooth surfaces
Ball bearings and Abnormal scratches, wear or flaking on Replace the shaft as-
needle bearings the rolling surfaces sembly

4-72
 4
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP

Part Criteria Action

Guide (1) and retainer • Check for any scorning or stepwise • Replace the guide
(2) � wear and retainer as a
set, if repair is im-
possible.
• Repair a small
�
scoring or scratch
�������� by lapping.
Solenoid valves A • Measure the clearance between the • Replace
and B body and the spool
D-d: 0.015 mm

��������

Relief valve • Measure the clearance between the • Replace

cover and the spool
D-d: 0.015 mm

��������

Relief valve • Check the set pressure • Adjust or replace

4-73
 4
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE

CONTROL VALVE
Construction

�� �� �� �� � � �� � ��

�
�

�� �� �� �� �� �� �� �� � �� � �� � �� �� �

��������

1. Tie rod 10. Arm section

2. Nut 11. Slew section
3. Bucket section 12. Dozer blade section
4. Boom section 13. Switch valve
5. Right travel section 14. Main relief valve
6. Inlet housing 15. Port relief valve
7. Left travel section 16. Anti-cavitation valve
8. Swing section 17. 2nd auxiliary section
9. 1st auxiliary section

4-74
 4
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE

Left travel section

� �

1. Spring holder
2. Spring
�� � �� 3. Spring holder
4. Cover
5. O-ring
� � � � � 6. Cover
7. Poppet
8. Spring
9. O-ring
10. Plug
11. Housing
� � � � 12. Spool
� �� ��������

Right travel section

� �

1. Spring holder
2. Spring
�� � �� 3. Spring holder
4. Cover
5. O-ring
� � � � � 6. Cover
7. Poppet
8. Spring
9. O-ring
10. Plug
11. Housing
� � � � 12. Spool
� �� ��������

Swing section

� � � 1. O-ring
��
�� 2. Wiper
3. Seal holder
4. Spring holder
5. Spring
6. Cover
7. Poppet
8. Spring
� 9. O-ring
10. O-ring
� � � 11. Housing
�� � � �������� 12. Spool

4-75
 4
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE

Boom section

� �

� �

��

��
��
� � � � � � � � ��
��

��
��
��

��
��
��
�� �� � �� �� � �� �� �� ��
��������

1. Spring holder 11. Spacer 21. Backup ring

2. Spring 12. Backup ring 22. Spool
3. Spring holder 13. O-ring 23. O-ring
4. Cover 14. Spring 24. Spring
5. O-ring 15. Poppet 25. Piston
6. Poppet 16. Spring holder 26. O-ring
7. Spring 17. Sleeve 27. Housing
8. O-ring 18. Backup ring 28. Spool
9. Poppet 19. O-ring
10. Spring 20. O-ring

Slew section

1. Spring holder
�� �� 2. Spring
�� 3. Spring holder
4. Cover
�� � � � 5. O-ring
�� �� 6. Cover
�����������
� � 7. Poppet
�����������
� � 8. Spring
�����������
9. O-ring
10. Poppet
11. Spring
12. O-ring
13. Housing
� � � �� � �������� 14. Spool

4-76
 4
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE

Arm section

� � � � � �

� � � � � 1. Spring holder
2. Spring
3. Spring holder
4. Cover
5. O-ring
6. Poppet
� � � � 7. Spring
�
�������� 8. O-ring

Bucket section

� � � ��
�� �� 1. Spring holder
� � 2. Spring
3. Spring holder
4. Cover
5. O-ring
6. Cover
7. Poppet
8. Spring
9. O-ring
� � � � �������� 10. Poppet

Dozer blade section

� � � �� 1. O-ring
�� 2. Wiper
3. Seal holder
4. Spring holder
� �� 5. Spring
6. Cover
7. Poppet
8. Spring
�
9. O-ring
� 10. O-ring
11. Housing
� � � �������� 12. Spool

4-77
 4
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE

Switch valve

1. Cover
2. Spring holder
�� � � �� 3. Spring holder
��
4. Spring
5. O-ring
� � � �� 6. Cover
� 7. Filter
8. Poppet
9. Spring
10. O-ring
11. O-ring
12. Housing
� � � �
�������� 13. Spool

1st auxiliary section

�� � � � � 1. Cover
2. Spring holder
3. Spring holder
� � � � � 4. Spring
5. Poppet
6. Spring
7. O-ring
8. O-ring
9. O-ring
� � � � 10. Housing
� �� 11. Spool
��������

1st auxiliary section (high flow)

�
�� � � � � � � 1. Cover
2. Spring holder
3. Spring holder
� � � � � 4. Spring
5. Poppet
6. Spring
7. O-ring
8. O-ring
9. O-ring
10. Housing
� �� � � � �
�������� 11. Spool

4-78
 4
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE

2nd auxiliary section

�� � � � � 1. Cover
2. Spring holder
3. Spring holder
� � � � � 4. Spring
5. Poppet
6. Spring
7. O-ring
8. O-ring
9. O-ring
10. Housing
� � � �
� �� �������� 11. Spool

Inlet housing
�

�
�
� �
�
1. Cover
2. Filter
3. O-ring
4. Cover
5. O-ring
� � 6. Housing
� �������� 7. Spool

Main relief valve

� �� �� � � �� �� �� �� � �

1. Housing 10. Spring

2. Plug 11. Spring
3. Sleeve 12. O-ring
4. Main poppet 13. Backup ring
5. Piston 14. O-ring
6. Needle valve 15. O-ring
7. Setscrew 16. O-ring
8. Washer 17. Washer
� � � �� �� � �������� 9. Lock nut

4-79
 4
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE

Port relief valve

� � �� �� �� � �� �� � � �

1. Housing 11. Lock nut

2. Plug 12. O-ring
3. Sleeve 13. Backup ring
4. Main poppet 14, O-ring
5. Piston 15, Backup ring
6. Needle valve 16, O-ring
7. Spring 17. O-ring
8. Spring 18. Wave washer
9. Setscrew 19. O-ring
� �� �� �� � �� � �� �������� 10. Washer

Anti-cavitation valve
� � �

1. Plug
2. Poppet
3. Spring
4. O-ring
5. Backup ring
� � � �������� 6. O-ring

4-80
 4
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE

Disassembly and assembly

For disassembly of the control valve, follow the procedure
below. For assembly of the control valve, follow the same
procedure as for disassembly in the reverse order.

Disassembly
Valve assembly
1. Loosen the nuts (1) and remove the tie rods (2), then
remove the sections.
Be sure to apply position marks to each section to
avoid mistakes during assembly.
Nut (1): 26.5 to 29.4 N·m �
� ��������

2. Remove the O-ring.

• The contact surface is of a metal seal. Pay attention
not to damage or make a dent on it.

��������

3. Remove the main relief valve and the port relief valve,
and then remove the O-ring from the relief valve.
• Do not disassemble unless necessary. The pressure
value set in the valve is changed if the lock nut is
loosened and the setscrew is turned.
• Do not further disassemble the port relief valve as it
is impossible to adjust pressure after reassembly.
Main relief valve: 69 to 78 N·m
Port relief valve: 69 to 78 N·m

��������

4. Remove the anti-cavitation valve (1), and then remove

the O-ring from the anti-cavitation valve.
Anti-cavitation valve: 69 to 78 N·m

��������

4-81
 4
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE

5. Remove the load check valve.

a. Remove the spring (3) and then the poppet (4).

�
�

��������

6. Remove the load check valve.

a. Take out the plug (3) and spring (4) and remove the �
poppet (5).
Plug: 31.4 ±1.0 N·m
b. Remove the O-ring (8) from the plug. �

��������

Manually operated section

1. Remove the cap screws, the cover (1) and the spool
assembly (2).
Cap screw: 8.8 to 10.8 N·m

2. Take out the seal holder and remove the wiper and the
O-ring.
�

��������

3. Take out the screws on the spool yoke side of the sec-
tion, and then remove the seal holder, wiper ring and
O-ring.
• When assembling, temporarily fasten the seal holder
with the screws and tighten them only after confirm-
ing that the spool turns smoothly.
Screw: 2.5 to 2.9 N·m

��������

4-82
 4
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE

Pilot operated section

1. Remove the cap screws and cover (1), and then re- �
move the O-ring from the cover (1). �
Cap screw: 8.8 to 10.8 N·m
�
2. Remove the spring holder (2), spring (3) and spring �
holder (4). �

3. Remove the spool (5) from the housing.

• Make sure to insert the spool in the correct direc-
tion.

��������

Boom section

WARNING
If the anti-drift valve is disassembled with the control
valve still installed, parts may be ejected due to the �
internal pressure. Remove it after relieving the internal �
pressure by gradually loosening the cap screw. �
�
1. Remove the cap screws and cover (1), and then re-
move the O-ring from the cover.
Cap screw: 8.8 to 10.8 N·m

2. Remove the spring holder (2), spring (3) and spring ��������

holder (4).

3. Take out the cap screws and housing (5), and then re-
move the O-ring from the housing.
• Do not further disassemble the anti-drift valve.
Cap screw: 8.8 to 10.8 N·m

4. Remove the spring holder (2), spring (3) and spring

holder (4). �

5. Remove the spool assembly (6) from the housing. �

• Make sure to insert the spool in the correct direc- �
tion.
�
� ��������

Switch valve
1. Remove the cap screws and cover (1), and then re-
�
move the O-ring from the cover (1).
Cap screw: 8.8 to 10.8 N·m

2. Remove the cap screws and cover (3), and then re-
move the O-ring from the cover (3). �
�
Cap screw: 8.8 to 10.8 N·m
�
3. Remove the spring holder (4), spring (5) and spring �
holder (6).
�
4. Remove the spool (7) from the housing.
• Be sure to insert the spool in the correct direction. � ��������

4-83
 4
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE

Main relief valve �

1. Remove the plug (1) from the housing (2).
Plug: 49 to 54 N·m

2. Remove the O-ring (3) from the plug (1).

�
�

��������

3. Remove the sleeve (4) from the plug (1), and then re-
move the spring (5) and the main poppet (6) from the �
sleeve (4).
�
�
4. Remove the O-ring (7) and the backup ring (8) from the
seat (9). � �

�
��������

5. Remove the lock nut (10), the washer (11) and the set- �
screw (12) from the plug (1), and then remove the O-
ring (13) from the setscrew (12).
• When assembling, first install the setscrew (12), and
then temporarily fasten the lock nut (10) to adjust ��
the pressure before final tightening. ��
Lock nut: 27.5 to 31.4 N·m

6. Remove the spring (14) and the needle valve (15). ��

��
��
�� ��������

4-84
 4
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE

Inspection and adjustment

Checking the parts
Parts Criteria Action
Housing, valve body • Scratches, rust or corrosion on the parts sliding against the • Replace
spool
• Scratches, rust or corrosion on the seal pocket part that • Replace
the spool enters
• Scratches, rust or corrosion on the seal part on the port • Replace
that is in contact with the O-ring
• Scratches, rust or corrosion on the seal part of the relief • Replace
valve, etc.
• Other damage considered to impair normal functions • Replace
Spool • Scratches on the sliding surface of outer circumference, on • Replace
which the fingernails get caught
• Scratches on parts that slide against the seals at both • Replace
ends
• Spool does not move smoothly • Repair or replace
Load check valve • Imperfect sealing due to damage to the valve or spring. • Repair or replace
• Operates smoothly when inserted and operated in the • Normal
housing
Around the springs • Rust, corrosion, deformation, breakage or other notable • Replace
damage to the spring, holder or cover
Around the spool seal • Oil leakage to the outside • Repair or replace
• Rust, corrosion or deformation of the seal holder • Repair or replace
Main relief valve, port re- • External rust, damage • Replace
lief valve, anti-cavitation • Damage to valve seat contact surface • Replace
valve • Damage to poppet contact surface • Replace
• Abnormality in the spring • Replace
• O-rings, backup rings, seals • Replace as a rule

Adjusting the main relief valve pressure

“2. Service data, Performance criteria”

4-85
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE

PILOT VALVE
Construction

18
16

�������� �������� 17
����������� �����������
��������������� ��������������� 6 5
7 2
4
8

9
10
15 14
13 12

11
��������
��������
�����������
�����������
���������������
��������������� 3
1

4KAC01Z

1. Casing 10. Spring seat

2. Plate 11. Washer 2
3. Spool 12. Spring
4. Plug 13. Spring
5. Push rod 14. Spring
6. Push rod 15. Spring
7. Seal 16. Joint
8. O-ring 17. Cam
9. Spring seat 18. Adjusting nut

4-86
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE

Special tools
Unit: mm
46
25
Installation jig A 17
Quantity: 1
Material A: S45C

ø31
ø27
ø23+0.2
16 +0.2

ø26.5
ø29
23.5
ø19
Material B: SCM415N (carburizing hardening)

0
+0.015
+0.028

+0.013
0
50
54 13
69 B
A
4KAC02Z

Installation jig B

R13
Quantity: 2
Material B: SCM415N (carburizing hardening)

0.5x15°
15.5±0.1 6.5 ±0.1
R5
.8 R4 C0.5
.5
12.5

9.5

C0.5
11.6 ±0.1
0
4KAC03Z

Disassembly
1. Take out the adjusting nut (1) and remove the cam (2)
from the joint. 1
• Secure the valve to the vice by using a copper or
lead plate. 2

4KAC04Z

2. Take out the joint (3), and then remove the plate (4).
• Use the installation jigs A and B.
A B

A
3 4

4KAC06Z 4KAC05Z

4-87
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE

3. Take out the plug (5) and remove the push rod (6) from
the plug (5).
• If it is hard to remove, use a flat-bladed screw-
driver. 6
• Watch out for the plug popping out due to spring
pressure.

4KAC07Z

4. Remove the O-ring (7) and the seal (8) from the plug.
7

8
4KAC08Z

5. Remove the reducing valve (12) and the spring (13).

• To avoid misconnection when reassembling, place
indicators showing the matching positions for the
reducing valve and the casing hole. 12

13

4KAC09Z

6. Disassemble the reducing valve.

a. Push in the spring seat (14) to compress the spring 14
(15) and to move the spool (17) from the small hole
side to the large hole side of the spring seat (14).
• The spring seat cannot be pushed down 6 mm or
more.

15 17
4KAC10Z

4-88
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE

7. Remove the spring seat (14), the spring (15) and the
washer 2 (16) from the spool (17).
14
15
16

17
4KAC11Z

Assembly
1. Assemble the reducing valve (12).
14
a. Install the washer 2 (16), the spring (15) and the 15
spring seat (14) on the spool (17). 16

17
4KAC11Z

b. Push in the spring seat (14) to compress the spring

(15) and to move the spool (17) from the large hole 14
side to the small hole side of the spring seat (14).
• The spring seat cannot be pushed down 6 mm or
more.

15 17
4KAC10Z

2. Install the spring (13) and the reducing valve (12).

• Install them in the locations where they were before
disassembly.
12

13

4KAC09Z

4-89
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE

3. Fit the O-ring (7) and the seal (8) to the plug (5).

7
5

8
4KAC12Z

4. Install the push rod (9) on the plug (5).

• Apply hydraulic oil to the push rod

9 5

4KAC14Z

9 4KAC13Z

5. Install the plug (5), the plate (4) and the joint.
• Use the installation jigs A and B to install the joint.
Joint: 41.7±2.9 N·m

A
4

4KAC05Z

6. Install the cam (2) and the adjusting nut (1).

• Tighten the adjusting nut (1) to the point where it
uniformly contacts all four push rods. 1
• When tightening the adjusting nut (1), do not move
the cam 2. 2
Adjusting nut: 68.6±4.9 N·m

4KAC04Z

4-90
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE

Grease the rotating part of the joint and its contact

surfaces with the disc and the push rod.

4KAC15Z

4-91
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE

Inspection and adjustment

Checking the parts
Part Criteria Action
O-ring — • Replace
Seal — • Replace
Spool • Wear on the sliding portions is 10 μm or greater com- • Replace
pared to the non-sliding portions.
• Scratches on the sliding portions • Replace
• Spool does not move smoothly • Replace
Push rod • Front end is worn 1 mm or more • Replace
• Scratches on the sliding portions • Replace
Plug • Seal is imperfect due to damage • Repair or replace
Controls • Tightening is loose at the pin, shaft or joint of the con- • Tighten to the specified torque
trols, with looseness of 2 mm or greater
• Due to wear, etc., tightening is loose at the pin, shaft or • Replace
joint of the controls, with looseness of 2 mm or greater
Casing, port plate • Scratches, rust, or corrosion at the sliding parts with the • Replace
spool
• Scratches, rust, or corrosion of the seal part in contact • Repair or replace
with the O-ring

4-92
 4
DISASSEMBLY AND ASSEMBLY
PROPORTIONAL CONTROL SOLENOID VALVE

PROPORTIONAL CONTROL SOLENOID VALVE

Construction

��������

1. Proportional control solenoid

2. Spool

4-93
 4
DISASSEMBLY AND ASSEMBLY
PROPORTIONAL CONTROL SOLENOID VALVE

Disassembly
For disassembly of the proportional control solenoid valve,
follow the procedure below. For assembly of the propor-
tional control solenoid valve, follow the same procedure as 1
for disassembly in the reverse order.

1. Take out the bolts and remove the proportional control

solenoid valve.
Bolt: 6.9 ±1 N·m

4KAD02Z

2. Remove the O-ring from the proportional control sole-

noid valve (1).
• Do not disassemble the sleeve (2) that is united with
the solenoid (4) with the retaining ring (3).
• Make sure that the spool (5) moves a little if pushed
from the sleeve (2) end.

4
3
2

5
4KAD03Z

Inspection and adjustment

Checking the parts
Part Criteria Action
Coil assembly • When the solenoid is burned, short-circuited, or has a • Replace
wire break
• Wiring short-circuit or wire break • Replace
Body • Scratches, rust, or corrosion at the sliding parts with the • Replace
spool
• Scratches, rust, or corrosion of the seal part in contact • Replace
with the O-ring
• Other damage considered to impair the normal func- • Replace
tions
Spool • Scratches on the outer circumference that easily catch • Replace
a fingernail
• Movement is not smooth • Repair or replace
Spring • Rust, corrosion, deformation, breakage, or other no- • Replace
table damage
O-ring — • Replace

4-94
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE (AUXILIARY)

PILOT VALVE (AUXILIARY)

Construction

�� �� �� ��

��
��

��

��������

1. Case 9. Spring seat

2. Cover 10. Washer
3. Plug 11. Spring
4. Seal 12. Spring
5. O-ring 13. Shaft
6. Push rod 14. Bushing
7. Shim 15. Cam
8. Spool 16. Ball

4-95
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE (AUXILIARY)

Special tool
(for removal of bush)

�� ����
����
��� ����
����
��
�

�� �

��

��������

Disassembly
1. Wash the pilot valve with detergent.
• Cover each port with a blank plug.

2. Insert a cushion plate between the pilot valve and the

vise, and secure the pilot valve.
Remove the bellows from the cover by pulling it up-
ward.

��������

3. Loosen the hexagon setscrew with a hexagon

wrench.
• Be careful as the torque required for loosening is
large.

��������

4. Place a steel bar (dia., 7 mm or less) on the cam shaft

and tap it lightly with a hammer.

��������

4-96
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE (AUXILIARY)

5. Remove the cam.

• Treat the cam and ball bearing as an integral assem-
bly (cannot be taken apart).
• Note down the position of the cam relative to the
cover.

��������

6. Loosen the cap screws with a hexagon spanner and

remove them.

��������

7. Remove the cover.

WARNING
When removing the cover, be careful as the push rod or
the plug may be ejected.
• Note down the position of the cover relative to the
casing.

��������

8. Remove the plugs together with the push rods, pack-

ing and O-ring.
• Note down the positions of the plugs relative to the
casing.

��������

4-97
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE (AUXILIARY)

9. Remove the pressure reducing valve assemblies and

the return springs from the casing.
• Note down the positions relative to the casing hole.

��������

��������

10. Place the cover sideways on a flat surface, and remove

the bush by applying the special jig and tapping it light-
ly with a hammer.

��������

11. To disassemble the pressure reducing valve, push

down the spring seat to compress the secondary
pressure spring and at the same time move the spring
seat sideways and pull out the spool through the larger
hole.
• Take care not to scratch the spool surface.
• Do not push down the spring seat by 4 mm or
more.
• When assembling, use the same set of parts as
above.

��������

4-98
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE (AUXILIARY)

12. Separate the spool, secondary pressure spring, shim

and washer.
• When assembling, use the same set of parts as
above.
• The washer is for adjusting the preset value of the
secondary pressure spring, and its thickness differs
for each spool assembly. In some cases this washer
is omitted.

��������

13. Remove the push rod from the plug.

��������

14. Remove the packing from the plug.

• Use a small flat head screwdriver or the like for re-
moval.
• Take care not to scratch the inner surface of the
plug.

��������

15. Remove the O-ring from the plug.

��������

4-99
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE (AUXILIARY)

Assembly
1. Install the wire, shim, secondary pressure spring and
spring seat on the spool, in that order.
• The washer is for adjusting the preset value of the
secondary pressure spring, and its thickness differs
for each spool assembly. In some cases this washer
is omitted.

��������

2. Insert the spool through the larger hole of the spring

seat, and while pushing down the spring seat to com-
press the secondary pressure spring, move the spring
seat sideways to install it.
• Take care not to scratch the spool surface.
• Do not push down the spring seat by 4 mm or
more.

��������

3. Secure the casing in a vise.

• Install the return springs in the casing.
• Install the return springs in the positions they were in
before disassembly.

��������

4. Install the pressure reducing valve sub-assemblies in

the casing.
• Install the sub-assemblies in the positions they were
in before disassembly.
• When installing the pressure reducing valve sub-as-
semblies, take care that the lower end of the spool
does not hit hard against the casing corners.

��������

4-100
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE (AUXILIARY)

5. Install the O-ring on the plug.

��������

6. Install the packing on the plug.

• Make sure that the packing is not installed in the
wrong way around.
• Apply a thin layer of grease to the packing before
installation.

��������

��������

7. Install the push rod on the plug.

• Apply hydraulic oil to the push rod before installa-
tion.
• Do not use excessive force to push in the packing to
prevent damage to the packing lip.

��������

8. Install the push rod sub-assemblies assembled in step

7 above in the casing.

��������

4-101
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE (AUXILIARY)

9. Place the cover sideways on a flat surface, and press

fit the bushing by using the special jig and tapping it
lightly with a hammer.
• Take care that the end of the bush does not pop out
of the cover.

��������

10. Install the cover in the casing.

• Install the cover in the position it was in before dis-
assembly.
• Take care that the cover is not lifted by the return
springs.

��������

11. Tighten the cap screws with the specified torque.

• Make sure that the cover is in a level position.
Cap screw: 8.8 ±0.1 N∙m

��������

12. Install the cam in the casing.

• Install the cam in the positions they were in before
disassembly.

��������

4-102
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE (AUXILIARY)

13. Insert the cam shaft while holding down the cam.
Apply grease to the sliding parts of the cam shaft
bearing.

��������

14. Apply Loctite to the hexagon setscrew.

Hexagon setscrew: Loctite #241 or equivalent

��������

15. Tighten the hexagon setscrew with the specified

torque.
Hexagon set screw: 6.9 ±1.0 N∙m

��������

16. Tilt the cam and apply grease to the head of the push
road.
To avoid scratching the surfaces of the push rod
and the plug when applying grease, use a spatula
made of a soft material.

��������

4-103
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE (AUXILIARY)

17. After attaching the upper end of the bellows to the

cam, insert the lower end into the groove of the cover.
• Before inserting the lower end of the bellows into the
groove of the cover, spray the inside of the bellows
with rust-inhibiting oil.
• Make sure to attach the bellows correctly. The dust-
proof and waterproof properties will be compro-
mised if the bellows is not firmly inserted into the
groove or is twisted in the groove.

��������

��������

4-104
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE (AUXILIARY)

Inspection and adjustment

Checking the parts
Part Criteria Action
O-ring — • Replace
Seal — • Replace
Spool • Wear on the sliding portions is 10 μm or greater com- • Replace
pared to the non-sliding portions.
• Scratches on the sliding portions • Replace
• Spool does not move smoothly • Replace
Push rod • Front end is worn 1 mm or more • Replace
• Scratches on the sliding portions • Replace
Plug • Seal is imperfect due to damage • Repair or replace
Controls • Tightening is loose at the pin, shaft or joint of the con- • Tighten to the specified torque
trols, with looseness of 2 mm or greater
• Due to wear, etc., tightening is loose at the pin, shaft or • Replace
joint of the controls, with looseness of 2 mm or greater
Casing, port plate • Scratches, rust, or corrosion at the sliding parts with the • Replace
spool
• Scratches, rust, or corrosion of the seal part in contact • Repair or replace
with the O-ring

4-105
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE (TRAVEL)

PILOT VALVE (TRAVEL)

Construction

�� �� �� ��

�
� ��
�

�
�
��
��
��

� �
��
��

��
��
�
��
��

��������

1. Case 9. Spring seat 17. O-ring

2. Cover 10. Washer 18. Grease cup
3. Plug 11. Spring 19. Piston
4. Seal 12. Spring 20. Spring
5. O-ring 13. Shaft 21. Ball
6. Push rod 14. Bushing 22. Spring seat
7. Shim 15. Cam 23. O-ring
8. Spool 16. Ball

4-106
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE (TRAVEL)

Special tools
(for bush removal)

Disassembly
1. Wash the pilot valve with detergent.

�� ����
����
��� ����
����
• Cover each port with a blank plug. ��
�

�� �

��

��������

2. Insert a cushion plate between the pilot valve and the

vise, and then secure the pilot valve.
Remove the bellows from the cover by pulling it up-
ward.

��������

3. Loosen the hexagon setscrew with a hexagon

wrench.
• Exercise caution, as the torque required for loosen-
ing is large.

��������

4. Apply a steel bar (dia., 7 mm or less) to one end of the

cam shaft and tap it lightly with a hammer.

��������

4-107
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE (TRAVEL)

5. Remove the cam.

• Handle the cam and ball bearing as an integral as-
sembly (cannot be taken apart).
• Note down the position of the cam relative to the
cover.

WARNING
When removing the cam, there is a risk that the push
rod (214) may pop out.

��������

6. Loosen the cap screws with a hexagon spanner.

��������

7. Remove the cover.

WARNING
When removing the cover, there is a risk that the push
rod and the plug may pop out.
• Note down the position of the cover relative to the
casing.

��������

4-108
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE (TRAVEL)

8. Remove the upper casing assembly and fix it in a vise.

• Note down the relative position of the upper casing
assembly so that it can be installed in the position it
was in before disassembly.

9. Pull out the push rods from the plugs.

• Note down the relative positions of push rod so that
it can be installed in the position it was in before
disassembly.

WARNING
• When removing the push rod, there is a risk that the
plug may pop out. ��������

• Take care not to scratch the push rod surface.

��������

10. Remove the plugs together with the grease cup, pack-
ing and O-ring.
• Note down the position of the plugs relative to the
casing.

WARNING
When removing the plugs, there is a risk that the piston
may pop out due to the damping spring force.

��������

11. Remove the pistons.

• Note down the position of the pistons relative to the
casing hole.

��������

4-109
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE (TRAVEL)

12. Remove the damping spring from the casing

• Note down the position of the damping spring rela-
tive to the casing hole.

��������

13. Pull out the spring seats from the casing by using twee-
zers or the like.
• Note down the position of the spring seat relative to
the casing hole.

��������

14. Remove the balls by using a magnet or the like.

• Make sure not to loose the balls.

��������

15. Secure the lower casing assembly in a vise, and then

remove the O-ring from the casing.

��������

4-110
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE (TRAVEL)

16. Remove the pressure reducing valve assemblies and

the return springs from the casing.
• Note down the positions relative to the casing hole.

��������

��������

17. Place the cover sideways on a flat surface, and remove

the bushing by applying the special jig and tapping it
lightly with a hammer.

��������

18. To disassemble the pressure reducing valve, push

down the spring seat to compress the secondary
pressure spring and at the same time move the spring
seat sideways and pull out the spool through the larger
hole.
• Take care not to scratch the spool surface.
• Do not push down the spring seat by 4 mm or
more.
• When assembling, use the same set of parts as
above.

��������

4-111
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE (TRAVEL)

19. Separate the spool, secondary pressure spring, shim

and washer.
• When assembling, use the same set of parts as
above.
• The washer is for adjusting the preset value of the
secondary pressure spring, and its thickness differs
for each spool assembly. In some cases this washer
is omitted.

��������

20. Remove the grease cup from the plug.

��������

21. Remove the packing from the plug.

• Use a small flat head screwdriver or the like for re-
moval.
• Take care not to scratch the inner surface of the
plug.

��������

22. Remove the O-ring from the plug.

23. Apply rust-inhibiting oil to each part.

• Storing the parts in the washed condition will lead to
the formation of rust and degrade their performance
after reassembly.

��������

4-112
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE (TRAVEL)

Assembly
1. Install the wire, shim, secondary pressure spring and
spring seat on the spool, in this order.
• The washer is for adjusting the preset value of the
secondary pressure spring and for adjusting the
spool assembly; its thickness differs for each spool
assembly. In some cases this washer is omitted.

��������

2. Insert the spool through the larger hole of the spring

seat, and while pushing down the spring seat to com-
press the secondary pressure spring, move the spring
seat sideways to install it.
• Take care not to scratch the spool surface.
• Do not push down the spring seat 4 mm or more.

��������

3. Fix the casing in a vise. Install the return springs in the

casing.
• Install the return springs in the positions they were in
before disassembly.

��������

4. Install the pressure-reducing sub-assemblies assem-

bled in steps 1 and 2 above in the casing.
• Install the sub-assemblies in the positions they were
in before disassembly.
• When installing the pressure reducing valve sub-as-
semblies, take care that the lower end of the spool
does not hit hard against the casing corners.

��������

4-113
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE (TRAVEL)

5. Install the O-rings in the casing.

��������

6. Secure the upper casing in a vise and install the balls.

��������

7. Install the spring seats with tweezers or the like in the

casing.
• Install the spring seats in the positions they were in
before disassembly.

��������

8. Install the damping springs in the casing.

• Install the damping springs in the positions they
were in before disassembly.
• Take care not to allow the damping spring to rest on
the spring seat.

��������

4-114
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE (TRAVEL)

9. Install the pistons.

• Install the pistons in the positions they were in be-
fore disassembly.

��������

10. Install the O-ring on the plug.

��������

11. Install the packing on the plug.

• Be sure to install the packing in the correct direc-
tion.
Apply a thin layer of grease to the packing before
installing it.

��������

��������

12. Install the grease cup on the plug.

��������

4-115
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE (TRAVEL)

13. Install the push rod on the plug.

• Apply hydraulic oil to the push rod before installing
it.
• Do not use excessive force to insert he push rod to
prevent the packing lip from damage.

��������

14. Install the push rod sub-assemblies assembled in steps

10, 11, 12 and 13 in the casing.

��������

15. Place the cover sideways on a flat surface, and press

fit the bushing by using the special jig and tapping it
lightly with a hammer.
• Take care that the end of the bushing does not pop
out of the cover.

��������

16. Secure the lower cover assembly assembled in steps

1 to 5 in a vise and install the upper cover assembly
assembled in steps 6 to 14 on it.
• Install the assemblies in the positions they were in
before disassembly.

��������

4-116
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE (TRAVEL)

17. Install the cover in the casing.

• Install the cover in the position it was in before dis-
assembly.
• Take care that the cover is not lifted by the damping
spring.

��������

18. Tighten the cap screws with the specified torque.

• Make sure that the cover is in a level position.
Cap screw: 8.8 ±0.8 N∙m

��������

19. Install the cam in the casing.

• Install the cam in the position it was in before disas-
sembly.

��������

20. Insert the cam shaft from the outside while holding
down the cam.
Apply grease to the sliding parts of the cam shaft
bearing.

��������

4-117
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE (TRAVEL)

21. Apply Loctite to the surface of the hexagon setscrew.

Hexagon setscrew: Loctite #241

��������

22. Tighten the hexagon setscrew with the specified

torque.
Hexagon setscrew 6.9 ±1 N∙m

��������

23. Tilt the cam and apply grease to the head of the push
road, and fill grease into the grease cup of the plug.
To avoid scratching the surfaces of the push rod
and the plug when applying or filling grease, use a
spatula made of a soft material.

��������

4-118
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE (TRAVEL)

24. After attaching the upper end of the bellows to the

cam, insert the lower end into the groove of the cover.
• Before inserting the lower end of the bellows into the
groove of the cover, spray the inside of the bellows
with rust-inhibiting oil.
• Make sure to attach the bellows correctly. The dust-
proof and waterproof properties will be compro-
mised if the bellows is not inserted into the groove
or is twisted in the groove.

��������

��������

4-119
 4
DISASSEMBLY AND ASSEMBLY
PILOT VALVE (TRAVEL)

Inspection and adjustment

Checking the parts
Part Criteria Action
O-ring — • Replace
Seal — • Replace
Spool • Wear on the sliding portions is 10 μm or greater com- • Replace
pared to the non-sliding portions.
• Scratches on the sliding portions • Replace
• Spool does not move smoothly • Replace
Push rod • Front end is worn 1 mm or more • Replace
• Scratches on the sliding portions • Replace
Plug • Seal is imperfect due to damage • Repair or replace
Controls • Tightening is loose at the pin, shaft or joint of the con- • Tighten to the specified torque
trols, with looseness of 2 mm or greater
• Due to wear, etc., tightening is loose at the pin, shaft or • Replace
joint of the controls, with looseness of 2 mm or greater
Casing, port plate • Scratches, rust, or corrosion at the sliding parts with the • Replace
spool
• Scratches, rust, or corrosion of the seal part in contact • Repair or replace
with the O-ring

4-120
 4
DISASSEMBLY AND ASSEMBLY
SOLENOID VALVE (1-SECTION)

SOLENOID VALVE (1-SECTION)

Construction

� �

� � � � � �
�

��������

1. Plug
2. Solenoid valve
3. O-ring
4. O-ring
5. Spring
6. Spool
7. Body

4-121
 4
DISASSEMBLY AND ASSEMBLY
SOLENOID VALVE (1-SECTION)

Disassembly
1. Take out the cap screws and remove the solenoid coil
(1).
• Place alignment marks on the solenoid and the body �
for easy reassembly.
• Take care not to let the push rod drop out.
Cap screw: 4.9 N·m

2. Remove the O-ring from the solenoid coil (1).

��������

3. Remove the plug (2), and then remove the O-ring from
the plug (2).
Plug: 23.5 N·m

4. Remove the spring (4) and the spool (3) from the
body.
• Note down the positions of the spool and the body
�
hole so that they can be installed in the positions
they were in before disassembly. �

�
��������

Assembly
For assembly, follow the same procedure as for disassem-
bly in the reverse order by referring to the construction dia-
gram.

4-122
 4
DISASSEMBLY AND ASSEMBLY
SOLENOID VALVE (1-SECTION)

Inspection and adjustment

Checking the parts
Part Criteria Action
Coil • When the solenoid is burned or short-circuited, or has a wire break • Replace
• Wiring short-circuit or wire break • Replace
Body • Scratches, rust or corrosion at the sliding parts and the spool • Replace
• Scratches, rust or corrosion of the seal part in contact with the O- • Replace
ring
• Other damage considered to impair normal function • Replace
Spool • Scratches on the outer circumference, on which the fingernails get • Replace
caught
• Movement is not smooth. • Repair or replace
Spring • Rust, corrosion, deformation, breakage or other notable damage • Replace
O-ring –– • Replace

4-123
 4
DISASSEMBLY AND ASSEMBLY
SOLENOID VALVE (2-SECTION)

SOLENOID VALVE (2-SECTION)

Construction

�
�

� � � � � � �
�����������
�����������
� � �����������
�

� �

��������

1. Plug
2. Solenoid valve
3. O-ring
4. O-ring
5. Spring
6. Spool
7. Body

4-124
 4
DISASSEMBLY AND ASSEMBLY
SOLENOID VALVE (2-SECTION)

Disassembly
1. Take out the cap screws and remove the solenoid coil
(1). �
• Place alignment marks on the solenoid and the body
for easy reassembly.
• Take care not to let the push rod drop out.
Cap screw: 3.92 N·m

2. Remove the O-ring from the solenoid coil (1).

��������

3. Remove the plug (2), and then remove the O-ring from
the plug (2).
Plug: 26.5 N·m

4. Remove the spring (4) and the spool (3) from the
body.
• Note down the positions of the spool and the body
hole so that they can be installed in the positions
they were in before disassembly.

��������

Assembly
For assembly, follow the same procedure as for disassem-
bly in the reverse order by referring to the construction dia-
gram.

4-125
 4
DISASSEMBLY AND ASSEMBLY
SOLENOID VALVE (2-SECTION)

Inspection and adjustment

Checking the parts
Part Criteria Action
Coil • When the solenoid is burned, short-circuited, or has a wire break • Replace
• Wiring short-circuit or wire break • Replace
Body • Scratches, rust, or corrosion at the sliding parts and the spool • Replace
• Scratches, rust, or corrosion of the seal part in contact with the O- • Replace
ring
• Other damage considered to impair normal function • Replace
• Scratches on the outer circumference, on which the fingernails get • Replace
Spool caught
• Movement is not smooth. • Repair or replace
Spring • Rust, corrosion, deformation, breakage, or other notable damage • Replace
O-ring –– • Replace

4-126
 4
DISASSEMBLY AND ASSEMBLY
CYLINDERS

CYLINDERS
Construction
Boom cylinder
� �� � �� � � � � � �� �� � �� �� �� � �� �� ��
��

�� �� �� �
�� ��
�� ��

�� �
� ��������

1. Rod Packing 10. Piston rod 19. Piston

2. Dust seal 11. Bushing 20. Wear ring
3. O-ring 12. Rod cover 21. Setscrew
4. Backup ring 13. Bushing 22. Ball
5. O-ring 14. Holder 23. Dust seal
6. Backup ring 15. Cushion seal 24. Dust seal
7. Piston packing 16. Collar 25. Grease fitting
8. Tube 17. Spacer 26. Grease fitting
9. Bushing 18. Cushion bearing

Arm cylinder
� �� � �� � � � � � �� �� � �� �� �� � �� �� �� �� �� �� ��

��

�� �� �� �� �� ��

�� �
� ��������

1. Rod Packing 11. Bushing 21. Setscrew

2. Dust seal 12. Rod cover 22. Ball
3. O-ring 13. Bushing 23. Cushion bearing
4. Backup ring 14. Holder 24. Cushion seal
5. O-ring 15. Cushion seal 25. Snap ring
6. Backup ring 16. Collar 26. Stopper
7. Piston packing 17. Spacer 27. Dust seal
8. Tube 18. Cushion bearing 28. Grease fitting
9. Bushing 19. Piston 29. O-ring
10. Piston rod 20. Wear ring

4-127
 4
DISASSEMBLY AND ASSEMBLY
CYLINDERS

Bucket cylinder

�� �� �� �� �� � � �� �� � �� �� � � � �� � �� ��

�� � � �� ��
��������

1. Piston packing 9. Tube 17. Bushing

2. Rod packing 10. Rod cover 18. Snap ring
3. Backup ring 11. Piston rod 19. Grease fitting
4. Dust seal 12. Piston 20. Grease fitting
5. O-ring 13. Piston packing holder 21. Wear ring
6. O-ring 14. Rod packing holder 22. Dust seal
7. Backup ring 15. Bushing
8. O-ring 16. Setscrew

Dozer blade cylinder

�� �� �� �� � � �� �� � �� �� � � � �� � ��

�� �� � � �� �� �� ��������

1. Piston packing 9. Tube 17. Bushing

2. Rod packing 10. Rod cover 18. Snap ring
3. Backup ring 11. Piston rod 19. Grease fitting
4. Dust seal 12. Piston 20. Grease fitting
5. O-ring 13. Piston packing holder 21. Wear ring
6. O-ring 14. Rod packing holder 22. Dust seal
7. Backup ring 15. Bushing
8. O-ring 16. Setscrew

4-128
 4
DISASSEMBLY AND ASSEMBLY
CYLINDERS

Swing cylinder

�� �� �� �� �� �� � �� �� �� �� � �� � � �� �� � � � �� � �� �� ��

� �� �� �� �� � ��
��������

1. Rod Packing 11. Bushing 21. Wear ring

2. Dust seal 12. Rod cover 22. Ball
3. O-ring 13. Bushing 23. Setscrew
4. Backup ring 14. Connector 24. Cushion bearing
5. O-ring 15. Stopper 25. Cushion bearing
6. O-ring 16. Retainer 26. Washer
7. Piston packing 17. Cushion seal 27. Bolt
8. Tube 18. Spacer 28. Dust seal
9. Bushing 19. Stopper 29. Dust seal
10. Piston rod 20. Piston 30. Grease fitting

4-129
 4
DISASSEMBLY AND ASSEMBLY
CYLINDERS

Special tools
0
Unit: mm -0.25
C D E

Installation jig B
Quantity: 1
Material: SS41
A B C D E F
Boom 64 (74) 49.8 (59.8) 15 6 30 70 (80)

F ±0.2
øB
øA
Arm 59 49.8 15 5 30 65
Bucket 54 44.8 15 5 30 60
Blade 67 54.8 15 5 30 73
Swing 54 44.8 15 5 30 60 4LAA03Z

Figures in ( ) refer to the head side.

Sliding jig C +0.5

30 A 0
Quantity: 1
Material: STKM13C

8°
A B C D E
Boom 22.5 101 99.7 –– 84

øB ±0.05
Arm 19.5 90.7 89.7 –– 75

+0.2
C +0.1
D
E
Bucket –– –– –– –– ––
Blade –– –– –– –– ––
Swing 25 90.5 88 70 50 R
R5

15°
50 2
80
4LAA04Z

Fitting jig D
Quantity: 1
Material: Nylon
A B C
Boom 105 103 95
2
øB
øA

Arm 95 93 85
øC

Bucket –– –– ––
Blade –– –– ––
Swing 95 93 85 5
45
83

4LAA05Z

Corrective jig E 20
Quantity: 1
Material: STKM13C
R3 R3
A B
°
15

Boom 115 100

øB +0.1

Arm 105 90
0

øA

Bucket –– ––
Blade –– ––
Swing 105 90
C

50
4LAA06Z

4-130
 4
DISASSEMBLY AND ASSEMBLY
CYLINDERS

This chapter describes mainly the procedure for the swing

cylinder. When disassembling/assembling a cylinder, check
its construction against the construction diagram on the
preceding page.

Disassembly
Cylinder assembly
1. Keep the cylinder in a level position by securing the
clevis of the tube in a vise and placing a wooden sup-
port under the other end.

2. Drain the remaining hydraulic oil from the cylinder.

• Move the piston rod slowly to prevent the hydraulic 4LAA07Z

oil from spurting out.

3. Disengage the anti-rotation lock of the rod cover.

• Since the anti-rotation lock is built into the cylinder
tube, take care not to damage the tube when disen-
gaging the lock.

4LAA08Z

4. Loosen the rod cover.

• Pull out the piston rod approximately 200 mm be-
forehand.
• Cover the piston rod to protect it from dents.

5. Pull out the piston rod assembly from the tube.

• Pull it out straight so as not to damage the sliding
surface.

4LAA09Z

Piston rod assembly

1. Secure the piston rod assembly in a level position.

4LAA10Z

4-131
 4
DISASSEMBLY AND ASSEMBLY
CYLINDERS

2. Remove the piston. �

�
<Boom cylinder arm cylinder swing cylinder>
a. Take out the setscrew (1) and remove the ball (2).
�
• The setscrew (1) is caulked in two places with a
punch. Grind off the caulked portions with a hand
drill. �
b. Remove the piston (3). �

c. Pull out the cushion bearing (4).

�
� ��������

<Arm cylinder>
d. Remove the snap ring (5).
e. Push in the cushion bearing (6) to release the stop-
per (7), and then remove the cushion bearing (6)
f. Remove the cushion seal (8). �

�
�
�
� ��������

<Swing cylinder>
d. Remove the screw (5). �
e. Remove the washer.
f. Remove the cushion bearing (6).
�

�
�

�
��������

<Bucket cylinder, blade cylinder>

a. Remove the setscrew (1).
b. Remove the piston (2), O-ring (3) and piston packing �
holder (4).
�
�

��������

4-132
 4
DISASSEMBLY AND ASSEMBLY
CYLINDERS

<Boom cylinder, arm cylinder>

3. Remove the holder assembly.

��������

4. Remove the rod cover assembly.

4LAA13Z

<Swing cylinder>
5. Separate the retainer (9) from the rod cover. ��
a. Remove the stopper (10).
b. Remove the connector (11), and then disconnect
the retainer (8) from the rod cover.

��

��
�
��������

Piston, piston packing holder

1. Remove the wear rings (10). 10
• Spread the wear ring just enough to disengage it in
axial direction.

2. Remove the piston packing from the piston.

11

4LAA16Z

4-133
 4
DISASSEMBLY AND ASSEMBLY
CYLINDERS

Holder
<Boom cylinder, arm cylinder>
1. Remove the O-ring (1) and the backup ring (2).

2. Remove the collar (3), cushion seal (4) and spacer (5). �

�
�
�

��������

Retainer �
<Swing cylinder> �
1. Remove the O-ring (1) and the backup ring (2).
�
2. Remove the stopper (3), spacer (4) and cushion seal
(5). �

��������

Rod cover
1. Remove the O-rings (20) and (21) and the backup ring
(22) from the outer diameter section of the rod cover. ��
��

��

��������

2. Remove the rod packing.

<Boom cylinder, arm cylinder, swing cylinder>
a. Remove the rod packing.

��������

4-134
 4
DISASSEMBLY AND ASSEMBLY
CYLINDERS

<Bucket cylinder, blade cylinder>

a. Remove the snap ring (24). ��
b. Remove the rod packing holder (25), the rod pack- ��
ing (22) and the backup ring (23). ��
��

��������

3. Remove the dust seal (26).

• Tap alternately on several points around the inner
circumference of the metal ring, gradually pushing 26
the seal out of the groove.

4LAA21Z

Clevis
1. Remove the dust seals from the tube and the piston
rod clevis.

4LAA22Z

2. Remove the bushing.

• Pull out the bushing by using a press and the sup-
porting metal (27)
27

4LAA23Z

4-135
 4
DISASSEMBLY AND ASSEMBLY
CYLINDERS

Assembly
Clevis
1. Using the installation jig B, press fit the bushings (28)
into the piston rod and tube.
B

28

4LAA24Z

2. Install the dust seal by using the supporting metal

(29).

29

4LAA25Z

Rod cover
1. Install the rod packing.
<Boom cylinder, arm cylinder, swing cylinder>
a. Install the rod packing.

��������

<Bucket cylinder, blade cylinder>

a. Install the backup ring (23), the rod packing (22) and ��
the rod packing holder (25). ��
b. Install the snap ring (24). ��
��

��������

4-136
 4
DISASSEMBLY AND ASSEMBLY
CYLINDERS

2. Install the dust seal (26).

• For a dust seal with a metal ring around its perim-
eter, use a supporting metal (30) for installation.

30

26
4LAA26Z

3. Install the backup ring (22) and the O-rings (20) and
(21).
• Make sure that the cut portion of the backup ring ��
does not get out of place. ��

��

��������

Retainer �
<Swing cylinder> �
1. Install the cushion seal (5), spacer (4) and stopper (3)
�
on the retainer.

2. Install the backup ring (2) and the O-ring (1) on the re- �
tainer.
�

��������

Holder
<Boom cylinder, arm cylinder>
1. Install the spacer (5) and the cushion seal (4), and then
press fit the collar (3).
�
2. Install the backup ring (2) and the O-ring (1).
�
�
�

��������

4-137
 4
DISASSEMBLY AND ASSEMBLY
CYLINDERS

Piston, piston packing holder

1. Install the piston packing on the piston. 34
<Boom cylinder, arm cylinder, swing cylinder>
a. Install the O-ring (34).
• If the O-ring is twisted after fitted, correct it.

4LAA29Z

b. Cover the piston with the sliding jig C, and then,

35
using the fitting jig D, quickly insert the slipper ring
(35).

D C 4LAA30Z

c. Since the slipper ring (35) has been extended when 34

it is installed, correct it using the corrective jig E.
35

4LAA31Z

<Bucket cylinder, blade cylinder>

a. Install the packing ring (31), the slipper ring (33) and 2 31 32 33 32 3
the backup rings (32).

4LAA28Z

4-138
 4
DISASSEMBLY AND ASSEMBLY
CYLINDERS

2. Install the wear ring (10).

• Spread the wear ring (10) just enough so that it can 10
be installed on the piston in axial direction.

11

4LAA16Z

Piston rod assembly

<Swing cylinder> ��
1. Install the retainer (9) on the rod cover.
a. Insert the retainer (9) into the rod cover.
b. Install the connector (11) at the joining surfaces of
the retainer (9) and the rod cover. Install the stopper
��
(10) in the groove of the connector (10).

��
�
��������

2. Install the rod cover assembly on the piston rod.

4LAA13Z

<Boom cylinder, arm cylinder>

3. Install the holder assembly on the piston rod.

��������

4-139
 4
DISASSEMBLY AND ASSEMBLY
CYLINDERS

4. Install the piston on the piston rod.

<Arm cylinder>
a. Install the cushion seal (8).
b. First, push the cushion bearing (6) in all the way.
Then, install the stopper (7) and pull the cushion �
bearing back again.
c. Install the snap ring (5).

�
�
�
� ��������

<Swing cylinder>
a. Install the cushion bearing (6). �
b. Install the washer.
c. Install the screw (5).
Screw: 41.2 N·m �

�
�

�
��������

<Bucket cylinder, blade cylinder>

a. Install the piston packing holder (4).
b. Fit the O-ring (3) to the piston (2) and install it. �
Piston: See the table below.
c. Tighten the setscrew (1). �
Piston, setscrew �
Piston Set screw
Cylinders (N·m) (N·m)
Boom 2020 31.5 �
Arm 1530 16.2
Bucket 824 ––
Blade 1638 –– ��������

Swing 1265 16.7

4-140
 4
DISASSEMBLY AND ASSEMBLY
CYLINDERS

Cylinder assembly
1. Secure the tube in a level position, and insert the piston
rod assembly into the tube.
• When inserting, align the center of the piston rod
with the center of the tube. Insert the assembly
straight so as not to damage the seal.

4LAA35Z

2. Tighten the rod cover.

Rod cover
Rod cover
Cylinders
(N·m)
Boom 647
Arm 530
Bucket ––
Blade ––
Swing 363

3. Bend down the lock rib on the tube and fit it into the
notch of the rod cover to lock it. 4LAA36Z

4-141
 4
DISASSEMBLY AND ASSEMBLY
CYLINDERS

Inspection and adjustment

Inspection after disassembly
Clean each part thoroughly with cleaning oil, then carry out
the following checks. When a cylinder has been disassem-
bled, replace all the seals with new ones.

1. Piston rod
• Replace the rod if there are cracks.
• If the threads are damaged, repair them or replace
the rod.
• If the plating layer of the plated portion is broken,
rusted or scratched, replace the rod.
• If the rod is bent more than the limit of 1 mm in 1 m,
replace it. (For the measurement method, refer to
the figure on the right.)
• If the inner diameter of the clevis bushing is worn,
replace the bushing.

Measuring the bend

a. Support the portion of the rod with the same diam-
eter at both ends on V-blocks.
b. Set a dial gauge at the center between the two
blocks.
c. Rotate the rod and take a reading of the maximum
and minimum run-out indicated by the dial gauge. If
the bending of the rod is within the above limit, yet is
bent a lot in a small distance so that it will not move
1/2
smoothly, replace the rod if it makes a squeaking
sound in the operation test after reassembly or if it
catches during movement.
4LAA37Z

2. Tube
• If there are cracks in the welded portion, replace the
tube.
• Replace the tube if the inside surface is scratched or
if it leaks hydraulic oil.
• If the inner diameter of the clevis bushing is worn,
replace the bushing.

3. Rod cover
• If the bushing inner diameter is worn and the clear-
ance with the piston rod is greater than 0.25 mm,
replace the bushing.
• If the inside surface of the bushing is scratched, and
the scratches are deeper than the depth of the coat-
ing layer, replace the bushing.

4-142
 4
DISASSEMBLY AND ASSEMBLY
CYLINDERS

Inspection after assembly

No load operation test
1. Place the cylinder in a horizontal position with no load.
2. Apply gentle pressure alternately to the ports at both
ends, operating the piston rod 5 or 6 times.

3. Make sure there is no abnormality in the operating con-

dition.

4LAA38Z

Leak test
External leak
1. Apply test pressure for 3 minutes each to the retraction
side and the extension side.

2. Make sure there are no abnormalities such as external

leakage or permanent deformation, etc. in the rod seal,
the rod cover mount, or in any welded portion.

Internal leak
1. Disconnect the extension side hose.
4LAA39Z

2. Apply test pressure to the retraction side for 3 min-

utes.

3. Measure the amount of oil that has leaked from the

extension side.
• The amount of leakage should be 1 mL/3 min or
less.

Bleeding air from the hydraulic cylinder

Bleed the air out of the cylinder when the cylinder is re-
moved or when the hydraulic piping, etc. is disconnected.
1. Start the engine and let it idle for approximately 5 min-
utes.

2. With the engine running at slow speed, extend and re-

tract the cylinder 4 or 5 times.
• Move the piston rod to a position 100 mm before
the end of the stroke, being careful not to relieve
air.

3. With the engine at top speed, repeat the operation in

(2), then with the engine running at slow speed, move
the piston rod to the stroke end to relieve air.

4-143
 4
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR

TRAVEL MOTOR
Construction
Hydraulic motor

�
�
��
��
��
��
�� ��
�� �

��
�� ��
��
��
��
�� ��
��
��
�� ��
� ��

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�
��
��
�
��
� � �

��������

1. Retainer 11. Spring 21. O-ring

2. Ball 12. Retainer 22. O-ring
3. Shaft 13. Bearing 23. O-ring
4. Cylinder block 14. Bearing 24. Backup ring
5. Valve plate 15. 2nd speed piston 25. Friction disc
6. Piston 16. Brake piston 26. Center disc
7. Shoe holder 17. Spring 27. Oil seal
8. Guide 18. Snap ring 28. Spring pin
9. Swash plate 19. O-ring 29. Pin
10. Pin 20. O-ring 30. Retainer

4-144
 4
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR

Reduction gears

�
�� ��
��
�
�� �� ��
� �
��

��
�
��
�
��
� ��

��
��
�� ��

��
��
��
��
��
�
�� ��

��

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1. Housing 11. Needle 21. Plate

2. Cover 12. Needle 22. Ring
3. Carrier 2 13. Floating seal 23. Plate
4. Gear B1 14. O-ring 24. Thrust washer
5. Gear B2 15. Bearing 25. Thrust washer
6. Gear S1 16. Thrust washer 26. Snap ring
7. Gear S2 17. Snap ring 27. O-ring
8. Pin 18. Snap ring 28. O-ring
9. Flange holder 19. Snap ring 29. O-ring
10. Snap ring 20. Ring

4-145
 4
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR

Counterbalance valve, 2nd-speed control valve, relief block assembly

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1. Valve body 10. Spool

2. Spool 11. Spring
3. Check valve 12. Plug
4. Spring 13. O-ring
5. O-ring 14. Spool
6. Spring guide 15. Spool
7. Spring 16. Shuttle
8. Cap 17. O-ring
9. O-ring 18. Ring

4-146
 4
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR

For assembly of the counter balance valve and the hydrau-

lic motor, follow the procedure below. For disassembly,
follow the same procedure as for assembly in the reverse
order by referring to the construction diagram.

Assembly
Counter balance valve and hydraulic motor
1. Secure the valve body in a vise and install the spool in
the valve body.
• Insert an aluminum plate or the like between the
motor and the vise to prevent the outer surface of
the valve body from being damaged.
• Do not further disassemble the spool assembly.

��������

2. Install the rings (1) and springs (2) on both ends of the
spool.

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3. Install the O-ring on the plug, and then tighten the plug
at both ends of the valve body.
Plug: 196 to 245 N·m

��������

4-147
 4
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR

4. Install the spool (19), spring (5) and spool (20) on the
spool (4).

5. Install the 2nd speed spool (4) on the body.

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6. Install the O-ring on the plug, and then attach the plug
to the valve body by tightening it.
Plug: 46 to 51 N·m

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7. Install the shuttle.

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8. Install the O-ring on the plug, and then attach the plug
to the valve body by tightening it.
Plug: 12 to 18 N·m

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4-148
 4
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR

9. Install the O-rings (large and small) on the valve body.

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10. Press fit the oil seal in the flange holder.

• Do not disassemble the oil seal unless necessary.
Add grease between the lips of the oil seal.

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11. Install the pin.

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12. Install the 2nd speed piston.

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4-149
 4
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR

13. Install the shaft on the flange holder.

• The bearing is press-fitted and thus it cannot be dis-
assembled.
• Be careful not to damage the oil seal with the shaft.

��������

14. Install the balls and the swash plate on the flange hold-
er.
• Apply hydraulic oil to the sliding surfaces of the
swash plate.

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15. Install the retainer (6), spring (8) and retainer (7) on the
cylinder block and secure them with the snap ring (9).
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16. Install the three pins (10) on the cylinder block.

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4-150
 4
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR

17. Install the piston (12) and guide (13) on the shoe holder ��
(11) to make the shoe holder assembly.
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18. Install the shoe holder assembly on the cylinder block

to make the cylinder block assembly.

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19. Install the cylinder block assembly on the flange hold-

er.
• Install the cylinder block assembly in such a manner
that the shoe will touch the swash plate.

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20. Install the center discs (14) on the groove of the flange ��
holder, and the friction discs (15) on the groove of the ��
cylinder block.
• Total number of center discs: 3
• Total number of friction disc: 2

��������

4-151
 4
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR

21. Install the two O-rings and two backup rings on the
brake piston.
• Install the O-rings inside and the backup rings out-
side.

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22. Install the brake piston assembly on the flange holder.

Apply grease to the O-rings, and make sure that
the seal material is not caught.

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23. Install the valve plate (21) and the retainer (22) on the
valve body, and install the springs in the spring holes.
• Install the valve plate (21) so that its copper surface
faces the cylinder block. ��
Apply grease to the valve plate and springs. Avoid ��
dropping them.
��

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24. Fill the flange holder with 100 ml hydraulic oil, and align
the valve body with the flange holder.

��������

4-152
 4
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR

25. Secure the hydraulic motor in a vise and tighten the

screws.
Screw: 51 to 64.7 N·m
• Insert an aluminum plate or the like between the
flange holder and the vise to prevent the outer sur-
face of the valve body from being damaged.

��������

Reduction gears
1. Install the bearing (17), snap ring (18) and bearing (17)
on the housing.
• Be careful not to install the bearing a wrong way.

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2. Fit the O-ring on the floating seat and install them in the
housing.
Apply grease to the O-ring.

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3. Install the floating seat and the O-ring on the flange

holder.
Apply grease to the O-ring.

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4-153
 4
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR

4. Assemble the housing and the hydraulic motor and se-

cure them with a snap ring.
• Fix the reduction gear and the flange holder with a C
clamp or a hydraulic press, and secure them with a
snap ring.

��������

��������

5. Install the thrust plate (3), ring (4), gear B1 (5), needle
(6) and thrust plate (7) on the pin, and then secure them �
with a snap ring (8). �
• Do not spread the snap ring more than necessary. �
• Install the snap ring with the edge facing the cover. �
�
6. Place the thrust collar (9) in the center of the thrust �
plate (7).
�

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7. Install the gear S1 on the carrier 2 and secure it using

the snap ring.

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8. Install the thrust washer, gear B2, needle and thrust

washer on carrier 2, and secure them with a snap
ring.

��������

4-154
 4
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR

9. Install the carrier 2 assembly on the housing.

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10. Install the O-ring on the housing.

11. Add 1.0 L lubricant.

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12. Mount the ring on the cover.

Apply grease.

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13. Install the cover on the housing.

• Align the notches on the housing with the plug holes
(G3/8).

��������

4-155
 4
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR

14. Mount the snap ring and secure the cover.

• Set a flat head screwdriver to the edge of the snap
ring and hammer it in around its circumference.

��������

15. Mount an O-ring on the plug (G3/8) and install it on the

cover.
Plug: 46 to 51 N·m

��������

16. Attach the O-ring on the plug (G3/8) and install it on the
cover.
Plug: 12 to 18 N·m

��������

4-156
 4
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR

Inspection and adjustment

Use limit for parts
Part Area checked Judgment criteria Treatment
Floating seal Sliding surface Abnormal scratches, wear or scorch- Replace
ing on the surface
Angular bearing Rolling surface Abnormal scratches, wear or flaking Replace
on the ball or race.
Planetary gear Gear tooth surface Abnormal scratches, wear or flaking Replace
of the tooth surface (if pitting covers
10% or more of the area engaging
with the tooth surface).
Inner race Rolling surface Abnormal scratches, wear or flaking Replace
on the rolling surface
Needle Needle surface Abnormal scratches, wear or flaking Replace
on the surface
Thrust washer Sliding surface Abnormal scratches, wear or scorch- Replace
ing on the surface
Housing, sun gear, Gear tooth surface Abnormal scratches, wear or flaking Replace
drive gear of the tooth surfaces (if pitting cov-
ers 10% or more of the area engag-
ing with the tooth surface).
Thrust plate Sliding surfaces Abnormal scratches, wear or scorch- Replace
ing on the surface
O-ring –– –– Replace
Shaft Oil seal surface Abnormal scratches, wear or scorch- Replace
ing on the surface
Ball bearing Sliding surfaces Abnormal scratches or flaking on the Replace
ball or race.
Oil seal –– –– Replace
Swash plate Sliding surface with the piston as- Abnormal scratches (0.02 mm or Replace
sembly more), wear or scorching on the sur-
faces
Cylinder block Cylinder block-to-piston assembly 0.04 mm or more Repair by lapping
clearance (#1000) or replace
Sliding surface with the valve plate Abnormal scratches (0.02 mm or both cylinder block
more), wear or scorching on the sur- and piston assembly.
faces
Piston assembly Piston assembly-to-cylinder block 0.04 mm or more
clearance
Sliding surface with the swash plate Abnormal scratches (0.02 mm or
more), wear or scorching on the sur-
faces
Play of piston shoe 0.04 mm or more Replace
Valve plate Sliding surface with the cylinder Abnormal scratches (0.02 mm or Repair by lapping
block more), wear or scorching on the sur- (#1000) or replace
faces both cylinder block
and piston assembly.

4-157
 4
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR

Part Area checked Judgment criteria Treatment

Valve body Sliding surface with the spool Abnormal scratches, wear or scorch- Replace both valve
ing on the surface body and spool.
Spool Sliding surface with the valve body Abnormal scratches, wear or scorch-
ing on the surfaces
Sliding surface with the check valve Abnormal scratches, wear or scorch- Replace both spool
ing on the surfaces and check valve
Check valve Sliding surface with the spool Abnormal scratches, wear or scorch-
ing on the surface
Spool and seat surfaces Contact with the seat along the en-
tire circumference

4-158
 4
DISASSEMBLY AND ASSEMBLY
SLEW MOTOR

SLEW MOTOR
Construction
Hydraulic motor

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1. O-ring 10. Retainer 19. Shoe holder

2. O-ring 11. Disc spring 20. Pin
3. O-ring 12. Retainer 21. Orifice
4. O-ring 13. Guide 22. Pin
5. Disc 14. Pin 23. Swash plate
6. Cylinder block 15. Valve plate 24. Bearing
7. Brake piston 16. Bearing 25. Housing
8. Spring 17. Snap ring 26. Cover
9. Shaft 18. Spring seat 27. Piston

4-159
 4
DISASSEMBLY AND ASSEMBLY
SLEW MOTOR

Reduction gears

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1. Plate 11. Thrust wire 21. Carrier 1

2. Oil seal 12. Race 22. Snap ring
3. Shaft 13. Needle 23. Race
4. Collar 14. Planetary gear B 24. Needle
5. Bearing 15. Thrust plate 25. Planetary gear A
6. Housing 16. Drive gear 26. Thrust plate
7. Bearing 17. O-ring 27. Plate
8. Plate 18. O-ring 28. Plug
9. Collar 19. Screw
10. Carrier 20. Sun gear

4-160
 4
DISASSEMBLY AND ASSEMBLY
SLEW MOTOR

Brake valve

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A: Relief valve
B: Timing valve
C: Check valve
D: Anti-rebound valve

1. O-ring 15. Piston 29. Washer

2. Poppet 16. Housing 30. Spring
3. O-ring 17. Backup ring 31. Body
4. O-ring 18. Shim 32. Check valve assembly
5. Backup ring 19. Shim 33. Spring
6. O-ring 20. O-ring 34. Sleeve
7. O-ring 21. O-ring 35. Orifice
8. O-ring 22. Spring 36. O-ring
9. Backup ring 23. O-ring 37. Body
10. Sleeve 24. Sleeve 38. O-ring
11. Seat 25. O-ring 39. Filter
12. Seat 26. O-ring 40. Washer
13. Spring 27. O-ring 41. Orifice
14. Cap 28. Spool

4-161
 4
DISASSEMBLY AND ASSEMBLY
SLEW MOTOR

Special tools
Oil seal press fitting jig A

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Collar installation jig B

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4-162
 4
DISASSEMBLY AND ASSEMBLY
SLEW MOTOR

Disassembly
Slew motor
1. Take out the cap screws and remove the anti-rebound
valve.

��������

2. Remove the cap screws to disassemble the motor into

the hydraulic motor (1) and the reduction gears (2).
• Place alignment marks on the hydraulic motor and
the reduction gears for easy reassembly.
• Secure the hydraulic motor in a vise. �

��������

Brake valve and hydraulic motor

1. Remove the cap screws and then the cover (3).
• Take care that the valve plate does not fall down.

��������

2. Remove the valve plate (4) and the pin (5) from the �
cover.
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3. Remove the bearing (6), O-ring (7) and pin (8) from the
cover. �

��������

4-163
 4
DISASSEMBLY AND ASSEMBLY
SLEW MOTOR

4. Disassemble the check valve. �

a. Remove the plug (9). ��
b. Remove the spring (10) and the check valve (11). ��

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5. Loosen the plug (12) and remove the relief valve.

• Do not loosen the nut (13) of the setscrew.
• Do not further disassemble the relief valve.

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6. Remove the O-ring (14), disc spring (15) and spring ��

seat (16).
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7. Remove the brake piston (17).

WARNING
In a work area where compressed air is used, metal ��������

fragments or other objects could fly. Wear protective

gear such as goggles and a protective face mask.
�
• Blow air into the brake release port PB, taking care ��
that the brake piston is not ejected.
• If the timing valve is disassembled first, it may be
difficult to pull out the brake piston.

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4-164
 4
DISASSEMBLY AND ASSEMBLY
SLEW MOTOR

8. Remove the cylinder block (18) and the disc (19).

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9. Remove the shoe holder (20) and the piston assembly �� �� �� ��

(21) from the cylinder block.

10. Remove the guide (22) and pin (23) from the cylinder
block.

��������

11. Take out the snap ring (24), and remove the retainer ��
(25), springs (26) and retainer (27) from the cylinder ��
block. ��
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WARNING
Components may pop out. Wear protective gear such
as goggles and a protective face mask.

• Remove the snap ring while pressing down the re-

tainer (25).

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12. Remove the swash plate (28).

13. Remove the shaft (29).

• Lightly tap the end face with a plastic hammer. �

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4-165
 4
DISASSEMBLY AND ASSEMBLY
SLEW MOTOR

14 Disassemble the timing valve. ��

��
a. Remove the plug (30).
��
b. Remove the spring (31), washer (32) and the spool
(33). �� ��
c. Remove the sleeve (34).

��������

Reduction gears � � � � � � �
1. Remove the O-ring (1) and the thrust plate (2).

2. Remove the drive gear (3). �

3. Remove the planetary gear (4), needle (5), inner race (6)
and thrust washer (7) from carrier 1 (8).

4. Remove the carrier 1 (8).

��������

5. Remove the sun gear (12) and the snap ring (19).
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6. Remove the carrier 2 (13).

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4-166
 4
DISASSEMBLY AND ASSEMBLY
SLEW MOTOR

7. Take out the cap screws, and then remove the thrust
place (14) from the carrier 2 (13). ��
• Secure the carrier 2 in a vise.
• The cap screws are locked with Loctite. Warm up
the screws for easy removal (using a portable dryer,
for example).

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8. Remove the planetary gear (15), needle (16), inner race

(17) and thrust washer (18) from carrier 2 (13).
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9. Remove the collar (9) and plate (10). �� �

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10. Remove the shaft (11).

• Take care that the shaft does not drop out.
• If it is difficult to remove, tap it lightly with plastic
hammer.
• If the housing, taper roller bearing, plate, shaft or
collar requires replacement, replace the entire hous-
ing assembly.
��

��������

4-167
 4
DISASSEMBLY AND ASSEMBLY
SLEW MOTOR

11. Remove the inner race of the bearing (20).

• A removed oil seal cannot be reused. �� ��
• Be careful not to damage the outer race of the bear-
ing.

12. Remove the oil seal (21).

• Removed oil seal cannot be reused.

��������

Anti-rebound valve �
1. Take out the plug (1) and remove the plug (2). �
�
2. Remove the check valve assembly (3).

3. Remove the sleeve (4). �

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4. Take out the plug (5) and remove the orifice (6). �

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5. Remove the orifice (7), washer (8) and filter (9). �

• Replace the filter every time you disassemble the �
anti-rebound valve. �

��������

4-168
 4
DISASSEMBLY AND ASSEMBLY
SLEW MOTOR

Assembly �
Anti-rebound valve �
1. Install the orifice (7), washer (8) and filter (9) on the valve �
body.
• Use a new filter.
Orifice: 4.9 N·m

��������

2. Install the orifice (6) on the body. �

Orifice: 2.45 N·m

3. Attach the O-ring on the plug (5) and install them on

the valve body. �
Plug: 61.8 N·m

��������

4. Install the sleeve (4) on the body. �

�
5. Install the check valve assembly (3) and spring (2) on �
the body.

6. Attach the O-ring on the plug (1) and install them on �

the valve body. �
Plug: 61.8 N·m �
�

��������

4-169
 4
DISASSEMBLY AND ASSEMBLY
SLEW MOTOR

Brake valve and hydraulic motor

1. Install the relief valve assembly.
• Tighten the plug (12).
Plug: 157±10 N·m

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2. Install the check valve assembly (11) and spring (10) on �

the housing. ��
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3. Attach the O-ring on the plug (9) and install them on
the housing.
Plug: 39.2 N·m

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4. Assemble the timing valve. ��

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a. Attach the O-ring on the sleeve (34) and install them
��
on the housing.
b. Fit the spool (33), washer (32) and spring (31) into �� ��
the hole of the sleeve.
c. Install the plug (30).
Plug: 84 ±5 N·m

��������

5. Install the retainer (27), spring (26), retainer (25) and ��

snap ring (24) on the cylinder block (18). ��
��
WARNING
�� ��
Components may pop out. Wear protective gear such
as goggles and a protective face mask.

• Remove the snap ring while pressing down the re-

tainer (25).
• Make the tapered surface (A) of the retainer (27) face
the cylinder block.
�
��������

4-170
 4
DISASSEMBLY AND ASSEMBLY
SLEW MOTOR

6. Install the pin (23) on the cylinder block. �� �� �� ��

Apply grease to the pin beforehand.

7. Install the guide (22).

8. Attach the piston assembly (21) on the shoe holder (2)

and install them on the cylinder block.
• Apply hydraulic oil to the sliding surfaces before-
hand.

��������

9. Press fit the shaft (29) into the housing.

10. Install the swash plate (28) on the housing.

Apply grease to surface (A) of the swash plate. �

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11. Install the cylinder block (18) and the disc (19) on the
housing. �� ��
• Make sure that the pin (23) is not coming off.

��������

12. Attach the O-ring on the brake piston (17) and install �
them on the housing. ��
• Make sure that the pin hole (B) is positioned as
shown in the figure.

��������

4-171
 4
DISASSEMBLY AND ASSEMBLY
SLEW MOTOR

13. Install the spring seats (16) and the disc spring (15) on ��
the housing.
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14. Install the O-ring (14) on the housing.

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15. Install the pin (8), bearing (6) and O-ring (7) on the cov- �
er.
Apply grease to the pin beforehand. � �

16. Install the pin (5) and the valve plate (4) on the cover �
Apply grease on the back of the valve plate (the
side facing the cover) in advance to prevent the
�
plate from dropping out.

��������

17. Install the cover (3) on the housing and secure it with
cap screws.
• Make sure that the pin and the valve plate are not
dropping out.
Cap screw: 128 ±7 N·m �

��������

4-172
 4
DISASSEMBLY AND ASSEMBLY
SLEW MOTOR

Reduction gears
1. Press fit the oil seal (13).
Apply grease on the perimeter and the mount of
the oil seal beforehand.
• Use press fitting jig A.
• Dimension of the oil seal press-fitted: 4.25 mm
��
������
2. Press fit the bearing (12).

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��������

3. Fill grease into the inner race of the taper roller bear-
ing.
Brand: Shell Albania Grease #2
Filling volume: 62 to 72 mL

��������

4. Install the shaft (11) on the housing.

Apply grease to the oil seal lip beforehand.

��

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5. Install the collar (9) and the plate (10). �� �

• Use press fitting jig B.
• Apply a load of 9800 N.

��������

4-173
 4
DISASSEMBLY AND ASSEMBLY
SLEW MOTOR

6. Install the inner race (17), needle (16) and planetary

gear B (15) on the carrier 2 (13).
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7. Install the thrust plate (14) on the carrier 2 (13) and

secure it with the cap screws. ��
Apply Loctite #242 to the cap screws.
Cap screw: 6.1 ±2.0 N·m

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8. Install the carrier 2 (13) on the housing.

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9. Install the sun gear (12) and the snap ring (19).
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4-174
 4
DISASSEMBLY AND ASSEMBLY
SLEW MOTOR

10. Install the carrier 1 (8).

11. Install the thrust washer (7), inner race (6), needle (5),
planetary gear A (4), drive gear (4) and thrust plate (2)
on the carrier 1 (8).

12. Install the O-ring (1) on the housing.

Slew motor
1. Assemble the hydraulic motor (1) and the reduction
gears (2) and secure them with the cap screws.
Cap screw: 107 ±6 N·m

2. Install the O-ring on the cover.

3. Mount the anti-rebound valve on the cover and secure

it with the cap screws.
Cap screw: 128 ± 7 N·m

4-175
 4
DISASSEMBLY AND ASSEMBLY
SLEW MOTOR

Inspection and adjustment

Use limit for parts
Brake valve
Part Judgment criteria Treatment
Check valve, piston • Deep scratches on sliding surfaces or severe roughness • Replace
• Clearance with the body is too large • Replace
• Deep scratches on the valve seat or unevenly seated • Replace
Body • Deep scratches on sliding surfaces or severe roughness • Replace
• There are scratches that cause oil to leak • Replace
Relief valve assembly • Abnormal drop in set pressure • Replace
• Unstable set pressure causes vibration • Replace
• Strong leakage due to faulty seating • Replace
Spring • Damaged or severely deformed • Replace

Hydraulic motor
Recommended
Part Standard dimension Treatment
replacement value
Clearance between 0.02 mm 0.04 mm Replace cylinder block
piston and cylinder and swash plate as-
bore sembly
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��������

Play (S) of piston and 0.15 mm 0.4 mm Replace cylinder block

shoe and swash plate as-
sembly

��������

Bearing Flaking or pitting Replace

on the rolling sur-
face

Cylinder block sliding Sliding surface is Repair by lapping

surface (1) rough (#1000 powder) or re-
�
place.

Port block sliding sur- Replace

face (2) �
��������

4-176
 4
DISASSEMBLY AND ASSEMBLY
SLEW MOTOR

Reduction gears
Part Judgment criteria Treatment
Drive gear • Gear teeth surfaces show pitting, peeling, etc. • Replace
Housing, internal gear • Excessive clearance with the motor joint due to wear of the • Replace
spline
Planetary gear • Gear teeth surfaces show pitting, peeling, etc. • Replace
• Needle rolling surfaces show flaking, peeling, etc. • Replace
Pinion • Gear teeth surfaces show pitting, peeling, etc. • Replace
• Excessive clearance with the shaft due to wear of the spline • Replace
Needle bearing, planetary • Needle and shaft rolling surfaces show flaking, peeling, etc. • Replace
shaft • Needle and shaft rolling surfaces show indentations, etc. • Replace
• Bearing rotation is abnormal (abnormal noise, rotation not smooth, • Replace
etc.)
Carrier, shaft • Clearance with planetary shaft is too large • Replace
Shaft • Excessive clearance with the pinion due to wear of the spline • Replace
Thrust washer • Excessive wear • Replace
Ball bearing, roller bearing • Bearing rotation is abnormal (abnormal noise, rotation not smooth, • Replace
etc.)
• Rolling surfaces show flaking, peeling, etc. • Replace
• Rolling surfaces show indentations, etc. • Replace
Collar, oil seal, O-ring • There are scratches that cause oil to leak • Replace

Brake valve
Adjusting the relief valve pressure
“2. Service data, Performance criteria”

Anti-rebound valve
Part Judgment criteria Treatment
Check valve • Deep scratches on sliding surfaces or severe roughness • Replace
• Clearance with the body is too large • Replace
• Deep scratches on the valve seat or unevenly seated. • Replace
Body • Deep scratches on sliding surfaces or severe roughness • Replace
• There are scratches that cause oil to leak • Replace
Spring, sleeve • Damaged or severely deformed • Replace

4-177
 4
DISASSEMBLY AND ASSEMBLY
SWIVEL JOINT

SWIVEL JOINT
Construction

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1. Shaft 8. O-ring
2. Hub 9. Backup ring
3. Flange 10. Dust seal
4. Thrust ring 11. Snap ring
5. Pin 12. Plug
6. Slipper seal 13. Dust seal
7. O-ring

4-178
 4
DISASSEMBLY AND ASSEMBLY
SWIVEL JOINT

For disassembly of the swivel joint, follow the procedure

below. For assembly of the swivel joint, follow the same
procedure as for disassembly in the reverse order.

Disassembly
�
1. Take out the bolts and remove the hub from the flange
(1).
• Secure the hub in a vise.
• When assembling, place a pipe on the stopper pin
of the shaft and check if the shaft smoothly rotates.
Bolt: 24.5 to 39.2 N·m

��������

2. Remove the O-ring (2), the snap ring (3) and the thrust
ring (4). �
• When assembling, make sure the snap ring rests
securely in the groove.

� ��������

3. Remove the shaft (5) from the hub.

• Place a knock pin (6) against the shaft end and tap
with a hammer.
• Select a knock pin made of copper, plastic, etc.
• When assembling, apply a thin coat of hydraulic oil
to the outer circumference of the shaft.

��������

4. Remove the dust seals from the shaft.

��������

4-179
 4
DISASSEMBLY AND ASSEMBLY
SWIVEL JOINT

5. Remove the seals from the inside diameter of the hub.

• Check the positions of the seals in the construction
diagram.
• Remove the O-rings with an eyeleteer or similar tool
with a sharp point on the end.
• Do not strongly deform or bend localized portions of
the slipper seal.
• When assembling, make sure that the O-rings are
not twisted.

��������

4-180
 4
DISASSEMBLY AND ASSEMBLY
SWIVEL JOINT

Inspection and adjustment

Inspection procedure and treatment
Inspection interval Inspection point Inspection procedure Treatment
2000 hours Seals preventing leakage Check if oil is leaking out If there is a leak, replace the O-
of oil to the outside rings
4000 hours All seals –– Replace all sealing parts
Disassemble and inspect All sliding parts Check for abnormal wear, Treat in accordance with the
regardless of leak scratches, corrosion, etc., due use limit for parts
to scorching, or trapping of for-
eign matter, etc.
Disassembly due to mal- All parts Check for abnormal wear, Treat in accordance with the
function scratches, corrosion, etc., due use limit for parts, but make
to scorching, or trapping of for- sure to replace the seal kit
eign matter, etc.

Use limit for parts

Hub, shaft
Part Judgment criteria Treatment
Sliding portion against the • Loss or peeling of high-frequency induction-hardened • Replace
seals surfaces due to wear, scorching, trapping of foreign
matter, etc.
Sliding portion of hub and • Abnormal wear or scratches of 0.1 mm depth or more • Replace
shaft other than the seals due to scorching, trapping of foreign matter, etc.
• Scratches of 0.1 mm depth or more • Repair with an emery
wheel
Sliding portion against the • Wear of 0.5 mm or more or abnormal wear • Replace
thrust ring • Wear of 0.5 mm or less • Repair to make surfaces
smooth
• Scratches due to scorching, seizing of foreign matter, • Repair to make surfaces
etc., which are within the wear limit of 0.5 mm and can smooth
be repaired

Flange
Part Judgment criteria Treatment
Sliding portion against the • Wear of 0.5 mm or more or abnormal wear • Replace
shaft end • Wear of 0.5 mm or less • Repair to make surfaces
smooth
• Scratches due to scorching, trapping of foreign matter, • Repair to make surfaces
etc., which are within the wear limit of 0.5 mm and can smooth
be repaired

Thrust ring
Judgment criteria Treatment
Wear of 0.5 mm or more or abnormal wear Replace
Wear of 0.5 mm or less Repair to make surfaces smooth
Scratches due to scorching, trapping of foreign matter, etc., which are within Repair to make surfaces smooth
the wear limit of 0.5 mm and can be repaired

4-181
 4
DISASSEMBLY AND ASSEMBLY
SWIVEL JOINT

Inspection after assembly

After assembly, perform a leak test using the apparatus
shown in the figure on each circuit.

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�

��������

1. Connect the pipe (3) coming from the hydraulic pump

(2) to the shaft (1) side port.

2. Connect the pressure gauge (5) to the hub (4) side.

• Increase the pressure gradually to 20.6 MPa while
adjusting the relief valve (6), and then perform a 1-
minute leak test.
• Open the neighboring ports on both sides and
check visually for leak from the ports.
• Check for external leakage by carrying out a color
check.

4-182
 4
DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER

AIR CONDITIONER
Construction

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1. Upper case 8. Unit case

2. Heater core 9. Sensor holder
3. Retainer 10. Thermistor
4. Clamp 11. Expansion valve
5. Blower motor 12. Temperature sensor insulation material
6. Blower fan 13. Stay
7. Evaporator 14. Sensing tube

4-183
 4
DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER

1. Removing the upper case

a. Remove the three screws (5 x 12).
b. Remove the 11 clamps (4) with a flat head screw-
driver.

� ��������

c. Remove the upper case by pulling it upward.

2. Replacing the blower motor

When installing the blower motor, be sure to check the
installation location shown on the figure on the right
and to observe the followings.
• The clearance (A) between the fan (6) and the case
must be 2 mm or more (on both sides)
• Align the center of the blower fan (6) with the center
of the case (B)

��������

� � �
�

��������

3. Replacing the evaporator

a. Pull out the evaporator (7) from the unit case (8). � �� �
b. Pull out the thermistor holder (10) together with the
sensor holder (9).
c. Install the thermistor properly on the fan located in
the third-row from the bottom of the new evapora-
tor.

�����

��������

4-184
 4
DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER

d. Install the evaporator (7) in the unit case (8), aligning �

the thermistor code with the position of (C).
�

��������

4. Replacing the expansion valve

a. Remove the nuts from the expansion valve (11) inlet ��
pipe and from the evaporator (7) inlet. � �
b. Strip off the insulation material (12) from the tem-
perature sensor, pull the sensing tube out of sensing
tube support stay (13), and separate the expansion
valve (11) from the evaporator.
c. Install a new expansion valve (11) on the evaporator
(7) using the prescribed tightening torque. �
Expansion valve inlet (C): 13.2±0.15 N·m
Evaporator inlet (D): 17.7±0.2 N·m
d. Install the sensing tube (14) properly, and apply the
insulation material (12) to the temperature sensor. ��
• When installing the expansion valve, take care ��
not to pinch the O-ring. ��

5. Replacing the heater core

a. Loosen the pipe retainers (3) and pull out the heater
core (2) from the unit case (8).
b. Place the new heater core (2) between the pipe re-
tainers (3), secure the heater core (2), and then in-
stall the new heater core (2) in the unit case (8).

��������

4-185
 4
DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER

Cautions on maintenance
To use an air conditioner efficiently and comfortably, per-
form inspection and maintenance of the machine on a reg-
ular basis. For cases that require a special tools or instru-
ments, such as for adding refrigerant gas, consult Takeuchi
or your service or sales dealer for assistance.
Run the air conditioner 2 to 3 times a month during the
season when it is not in use to prevent the oil from drying
up in the compressor. Check for refrigerant gas leaks at the
same time. Leaving the air conditioner for extended periods
of time while oil is leaking will cause internal parts to rust
and will eventually cause a breakdown.

Checking the refrigerant

Set the air conditioner temperature to COOL MAX, raise
the engine speed, and then check the refrigerant condi-
tion in the refrigerant circuit through the sight glass of the
receiver-dryer.
a. Flow includes no bubbles: Proper level
b. Flow contains bubbles: Low level
c. Flow is clear and colorless: No refrigerant

IMPORTANT
The presence of bubbles indicates that the system is
low on refrigerant. Immediately add refrigerant to avoid
damage to the compressor.

Inspection and maintenance interval

Maintenance interval
Inspection point Check item Replacement
Daily inspection Monthly Every 6 months
interval
Condenser Clogging, dirt Yes Yes
Belt Slack, damage Yes Every 2 years
Refrigerant gas Refrigerant level Yes
Looseness, damage,
Piping Yes
leak
Receiver-dryer –– Every 2 years

4-186
 TROUBLESHOOTING 5
Overall machine ............................................................................................................................................................. 5-3
No operation is possible. .......................................................................................................................................... 5-3
All systems working, but insufficient power. .............................................................................................................. 5-4
Boom, bucket, slew and arm fail to move or are too slow. ........................................................................................ 5-6
Traveling ........................................................................................................................................................................ 5-8
Right or left travel is impossible ................................................................................................................................ 5-8
Right or left travel speed drops causing the machine to veer to one side ................................................................ 5-10
Machine will not travel in 2nd speed ....................................................................................................................... 5-12
Slewing ...................................................................................................................................................................... 5-15
No slewing ............................................................................................................................................................. 5-15
Does not slew to the right or left ............................................................................................................................. 5-17
Slewing is slow or lacks power ............................................................................................................................... 5-19
The machine slews, but the overrun when slewing stops is large, or slewing cannot be stopped ........................... 5-21
When stopped on a slope, the slewing mechanism cannot maintain its posture ..................................................... 5-23
Boom ......................................................................................................................................................................... 5-24
The boom cylinder does not move ......................................................................................................................... 5-24
Boom cylinder operation is slow or lacks power ..................................................................................................... 5-26
When the boom control lever is pulled slowly, the boom drops at first .................................................................... 5-29
Spontaneous drop of the bucket is too large .......................................................................................................... 5-30
Arm ............................................................................................................................................................................. 5-31
Arm cylinder does not move ................................................................................................................................... 5-31
Arm cylinder is slow or the power is insufficient. ..................................................................................................... 5-33
Spontaneous drop of the arm is too large .............................................................................................................. 5-35
Bucket......................................................................................................................................................................... 5-36
Bucket cylinder does not move or lacks power ...................................................................................................... 5-36
Spontaneous drop of the bucket is too large .......................................................................................................... 5-38
Boom swing ................................................................................................................................................................ 5-39
Swing cylinder does not move................................................................................................................................ 5-39
Blade ........................................................................................................................................................................... 5-41
Blade cylinder does not move or lacks power ........................................................................................................ 5-41
The spontaneous drop of the blade is too large, or the blade cannot support the machine..................................... 5-43
Auxiliary hydraulics ...................................................................................................................................................... 5-45
Proportional control does not work......................................................................................................................... 5-45
Piston pump ................................................................................................................................................................ 5-46
Gear pump .................................................................................................................................................................. 5-47
Control valve................................................................................................................................................................ 5-48
Pilot valve .................................................................................................................................................................... 5-50
Proportional control solenoid valve............................................................................................................................... 5-51
Cylinders ..................................................................................................................................................................... 5-52
Travel motor ................................................................................................................................................................ 5-53
Slew motor .................................................................................................................................................................. 5-55
Air conditioner ............................................................................................................................................................. 5-57

5-1
 5
TROUBLESHOOTING

This “Troubleshooting” section describes the fault diagnosis and corrective actions mainly for hydraulic systems. The cause
of the problem can be investigated by following the arrows in the chart shown at the beginning of each item.

Notes on troubleshooting and servicing

1. Do not disassemble the faulty part without first investigating the following.
a. Ask the user the following questions.
• The situation when the fault occurred.
• Any abnormalities or changes before the fault occurred.
• Any faulty parts other than the part in question.
• Any identical failure in the past
b. Drive the machine yourself and confirm the faulty condition.
• Determine if it is really faulty by referring to the performance criteria. Note that such determination may differ de-
pending on the person.

Important: By operating the user’s machine, you could make a bad situation worse. Therefore, before driving the
machine, always ask the user’s permission to do so.
c. Determine the cause of trouble based on the information obtained from the user and by driving the machine yourself.
Also remember that once the machine has been disassembled, it is almost impossible to reproduce the conditions
of the trouble, and so there will be no second chance to find out the true cause. Therefore be sure to find the true
cause of the trouble before attempting disassembly.

2. When multiple causes are suspected, start with the simplest one.

3. Think why the trouble occurred and try to correct the root cause of the problem.

5-2
 5
TROUBLESHOOTING
OVERALL MACHINE

OVERALL MACHINE
No operation is possible.

Check the hydraulic oil Insufficient

1 Add hydraulic oil.
level

Sufficient

• Repair or replace the hy-

Check the hydraulic Faulty
2 draulic pump.
pump
• Replace the coupling.

1. Check the hydraulic oil level.

Check the hydraulic oil tank level.
“4. Disassembly and assembly, Hydraulic oil
tank”
When adding, use the same brand of oil currently being
used.
“2. Service data, Fuel and lubricant table”

2. Check the hydraulic pump.

• Check the discharge pressure of the pumps P1 and
P2 (piston pumps).
“2. Service data, Performance criteria”
“5. Troubleshooting, Piston pump”
• Check the pumps P3 and P4 (gear pumps).
“2. Service data, Performance criteria” P4 P3 P2 P1
“5. Troubleshooting, Piston pump”

2DAA01Z

5-3
 5
TROUBLESHOOTING
OVERALL MACHINE

All systems working, but insufficient force.

Check the hydraulic oil Insufficient

1 2 Add hydraulic oil.
level

Sufficient

Abnormal noise from the Yes Replace the seal tape, O-ring
3 Suction line faulty
piston pump and hose.

No

Action appropriate to the

Frothing in the tank
cause of the frothing.

Check the main relief Faulty Repair or replace the main re-
4
valve lief valve.

Normal

Repair or replace the faulty

5 Piston pump is faulty
piston pump.

1. Check the hydraulic oil level.

“4. Disassembly and assembly, Hydraulic oil
tank”

2. Add hydraulic oil.

“5-3”

3. Abnormal noise from the piston pump.

The noise is likely to be caused by cavitation in the
pump, due to a faulty suction line. Check the follow-
ing.
a. The line for sucking the hydraulic oil
• Apply grease or oil on the suspected faulty sec-
tions and check for a change (check if air is being
sucked).
b. Clogging in the suction filter
c. Pressurize the hydraulic tank.
“4. Disassembly and assembly, Hydraulic
tank”

5-4
 5
TROUBLESHOOTING
OVERALL MACHINE

4. Check the main relief valve.

Measure the relief pressure of the main relief valve.
• If the measured value is within specifications, the
valve is normal.
“2. Service data, Performance criteria”
If the pressure of the main relief valve is low, adjust
it to the set pressure by gradually tightening the set-
screw.
• If the pressure does not increase after tightening the
setscrew by 1/4 turn, the relief valve is faulty.

5. Piston pump is faulty.

If the inside of the pump is excessively worn or dam-
aged, it is likely that metal pieces are in the hydraulic
oil. If this is the case, do the following.
• Replace the elements of the line filter and the spin
filter.
• Replace the hydraulic oil or perform flushing.
• When replacing the hydraulic oil, clean the tank and
the suction strainer.
“4. Disassembly and assembly, Piston pump”

5-5
 5
TROUBLESHOOTING
OVERALL MACHINE

Boom, bucket, slew and arm fail to move or are too slow.

• Repair or replace the gear

Faulty
1 Check the gear pump pump
• Replace the coupling
Normal

Faulty
2 Check the fuse Replace the fuse

Normal

Faulty Adjust or replace the limit

3 Check the limit switch
switch

Normal

Check the lever lock sole- Faulty Repair or replace the lever
4
noid valve lock solenoid valve

Normal

Check the pilot relief Faulty Repair or replace the pilot re-
5
valve lief valve

Normal

Faulty Repair or replace the pilot

6 Check the pilot valve
valve

1. Check the gear pump

Check the hydraulic pump (1) which supplies hydraulic
pressure to the pilot valve.
• The inspection procedure is the same as for the pis-
ton.
“5-3”
Also, check the line filter for clogging, and clean it as
necessary.

�������
������� �������
��������

5-6
 5
TROUBLESHOOTING
OVERALL MACHINE

2. Check the fuse

Check the fuse in the power supply circuit that oper-
ates the pilot solenoid valve.

��������

3. Check the limit switch ����������������

Turn the limit switch on, by moving the lever stand to
the driving position. ������
Then check the voltage at the lever lock solenoid valve
with a tester.
If there is voltage, the switch works normally.

������� ��������

4. Check the lever lock solenoid valve

Check according to the following procedure.
a. Turn the starter switch to the ON position.
b. Lightly press down the protruding part on the sole-
noid valve.
c. Move the lever stand to turn on the limit switch.
d. If you feel vibration under your fingers when the
spool is moved and the circuit is switched, the sole-
noid valve is normal.

���������������� ������� ��������

5. Check the pilot relief valve

Measure the relief pressure of the pilot relief valve.
• If the measured value is within specifications, the
valve is normal.
“2. Service data, Performance criteria”

6. Check the pilot valve

“4. Disassembly and assembly, Pilot valve”

5-7
 5
TROUBLESHOOTING
TRAVELING

TRAVELING
Right or left travel is impossible

Check the operation of

1 actuators other than of
the travel motor
Normal

Check the pilot valve Faulty Repair or replace the pilot

2
(Travel) valve (travel)

Normal

Check the spool opera- Faulty Repair or replace the housing

3
tion block

Normal

Faulty Repair or replace the swivel

4 Check the swivel joint
joint

Normal

Check the counter bal- Faulty Repair or replace the counter

5
ance valve balance valve

Normal

Faulty Repair or replace the travel

6 Check the travel motor
motor

1. Check the operation of actuators other than of the Device to check

Lever to
travel motor. Problem
operate Relief valve Pump
If the right or left travel is impossible, operate each ac-
Right TB228, 235: R2 TB228, 235: P2
tuator of the devices listed in the table on the right. Boom
travel TB250: R1 TB250: P1
If operation is faulty, inspect the main relief valve and
piston pump. TB228, 235: R1 TB228, 235: P1
Left travel Arm
TB250: R2 TB250: P2

2. Check the pilot valve (travel)

Disconnect the hose connecting the pilot valve and the ���
control valve (travel block) from the control valve. Fit a ���
pressure gauge to the hose just disconnected.
• Insert a plug into the control valve port.
• Operate the lever (travel) and measure the pres- ���
sure. ��� ���
• If the pressure is between 0 and 3.4 MPa depending ���
on the lever angle, the pilot valve is normal. ��� ���

��������

5-8
 5
TROUBLESHOOTING
TRAVELING

3. Check the spool operation

Disconnect the hose connecting the control valve (trav-
��
el block) and the swivel joint from the control valve. Fit
the pressure gauge to the discharge port on the con- ��
��
trol valve.
• Operate the lever (travel) and measure the pres- ��
�
sure.
�
• If the measured value is as below, the spool is nor- �
mal. �
Supply pressure: 21.0 MPa

��������

4. Check the swivel joint

• Disconnect the hose connecting the swivel joint and
the counter balance valve from the counter balance
valve. Fit the pressure gauge to the hose just dis-
connected.
• If the measured value is within specifications, the
swivel joint is normal.
“2. Service data, Performance criteria”

��������

5. Check the counter balance valve � �

• If neither forward nor reverse travel is possible, the
spool (1) of the counter balance valve could be
sticking in the neutral position.
• If either forward or reverse travel is possible, the
spool (1) of the counter balance valve could be stick-
ing in a position other than the neutral position.
• Remove the counter balance valve plug (2) and push
the spool (1) with a finger. If it moves smoothly about
6 mm, the counter balance valve is normal.

��������

6. Check the travel motor

“4. Disassembly and assembly, Travel motor”

5-9
 5
TROUBLESHOOTING
TRAVELING

Right or left travel speed decelerates, causing the machine to veer to one side

Is the veering within Within specs Problem is caused by the

1 Normal
specs? combination of devices

Out-of-specs

Check the crawler belt Adjust to the specified crawler

tension. Check for for- Faulty
2 eign matter caught in the tension and remove the for-
crawler belt eign matter
Normal

Check the spool opera- Faulty Repair or replace the housing

3
tion block

Normal

Veering is changed to the op- • Repair or replace the pumps

Switch the discharge hos- posite side
4 • Replace the hydraulic oil or
es between the pumps
the filter
No change

Veering is changed
Test by switching the main to the opposite side Check the main relief Repair or replace the faulty
5
relief valves valve main relief valve

No change

Faulty Repair or replace the swivel

6 Check the swivel joint
joint

Normal

Check the counter bal- Faulty Repair or replace the counter

7
ance valve balance valve

Normal

Travel motor reduction Repair or replace the travel

8
gears are faulty motor

5-10
 5
TROUBLESHOOTING
TRAVELING

1. Is the veering within specs?

If the veering is within specifications, the machine is
normal. Problem is caused by the combination of de-
vices.
“2. Service data, Performance criteria”

2. Check the crawler tension

“2. Service data, Performance criteria”

3. Check the spool operation

“5-9”

4. Switch the discharge hoses between the pumps

Switch the discharge hoses between the pumps P1
and P2. If the veering direction is changed to the op-
posite side, the pumps are faulty.
• Disassemble and check the pump
“4. Disassembly and assembly, Hydraulic pump”

��������

5. Test by switching the main relief valves

Switch the main relief valves between the right travel
circuit and the left travel circuit, and operate the ma-
chine. If the veering is changed to the opposite side,
one of the main relief valves is faulty.
• Check the main relief valve
“5-5”

��������

6. Check the swivel joint

“5-9”

7. Check the counter balance valve

Check to see if the spool of the counter balance valve
moves smoothly.
“5-9”

8. Check the travel motor reduction gears

“4. Disassembly and assembly, Travel motor”

5-11
 5
TROUBLESHOOTING
TRAVELING

2nd speed travel is not possible

Faulty Repair or replace the gear

1 Check the gear pump
pump

Normal

Check the pilot relief Faulty Adjust, repair or replace the

2
valve pilot relief valve

Normal

Faulty
3 Check the fuse Replace the fuse

Normal

Check the 2nd speed Faulty Replace the 2nd speed

4
switch switch

Normal

Check the 2nd speed re- Faulty

5 Replace the 2nd speed relay
lay

Normal

Check the 2nd speed so- Faulty Repair or replace the 2nd
6
lenoid valve speed solenoid valve

Normal

Faulty Repair or replace the swivel

7 Check the swivel joint
joint

Normal

Check the 2nd speed Faulty Repair or replace the 2nd

8
control valve speed control valve

1. Check the gear pump

Check the gear pump that supplies hydraulic pressure
for the 2nd speed switching.
“5-3”
Also, check the line filter for clogging, and clean it as
necessary.

5-12
 5
TROUBLESHOOTING
TRAVELING

2. Check the pilot relief valve

Measure the relief pressure of the pilot relief valve.
• If the measured value is within specifications, the pi-
lot relief valve is normal.
“2. Service data, Performance criteria”

3. Check the fuse

Check the fuse in the power supply circuit that acti-
vates the 2nd speed solenoid valve.

��������

4. Check the 2nd speed switch

Press the switch to turn it on. Then check for continuity
with a tester.

��������

5. Check the 2nd speed relay ����������������

Press the travel speed switch to turn on the relay. Then, ������

check the voltage in the 2nd speed solenoid valve with

a tester.
Be sure to stop the engine before checking.

������� ��������

5-13
 5
TROUBLESHOOTING
TRAVELING

6. Check the 2nd speed solenoid valve

a. Turn the starter switch to the ON position.
b. Lightly press down the protruding part on the sole-
noid end.
c. Move the lever stand to turn on the limit switch.
d. If you feel vibration under your fingers when the
spool is moved and the circuit is switched, the sole-
noid valve is normal.

���������������� ������� ��������

7. Check the swivel joint

Disconnect the hose connecting the swivel joint and
the 2nd speed control valve from the 2nd speed con-
trol valve. Fit the pressure gauge to the hose just dis-
connected, and then turn on the 2nd speed switch.
• Supply pressure: 3.4 MPa

��������

8. 2nd speed control valve is faulty

Check if the spool of the 2nd speed control valve is
sticking or if foreign matter is caught in the spool.
“4. Disassembly and assembly, Travel motor”

5-14
 5
TROUBLESHOOTING
SLEWING

SLEWING
No slewing is possible

Check the operation of

1 actuators other than of
the slew motor
Normal

Faulty Repair or replace the pilot

2 Check the pilot valve
valve

Normal

Check the spool opera- Faulty Repair or replace the housing

3
tion block

Normal

Pressure too low Adjust the pressure of the

4 Check the slew pressure Adjust to the set pressure
slew relief valve

Normal

Pressure does not rise Repair or replace the relief

valve

Faulty Repair or replace the slew

5 Check the slew motor
motor

Normal

Slew bearing is faulty Replace

1. Check the operation of actuators other than of the Device to check

slew motor Lever to operate
Relief valve Pump
Determine if only the slew motor is faulty by checking
Blade R3 P3
the operation of actuators for the devices listed in the
table on the right. If one of them is faulty, check the
main relief valve and the hydraulic pump (main).
“5-5”

5-15
 5
TROUBLESHOOTING
SLEWING

2. Check the pilot valve

Disconnect the hose connecting the pilot valve and the
control valve (slew block) from the control valve. Fit the
pressure gauge to the hose just disconnected.
• Insert a plug into the control valve port.
• Operate the lever (slew) and measure the pressure.
• If the pressure is between 0 and 3.4 MPa depending
on the lever angle, the pilot valve is normal.

3. Check the spool operation

Disconnect the hose connecting the control valve (slew
block) and the slew motor from the control valve. Fit
the pressure gauge to the discharge port on the con-
trol valve.
• Operate the lever (slew) and measure the pressure.
• If the measured value is as below, the spool is nor-
mal.
Supply pressure: 19.6 MPa

4. Check the slew pressure

Measure the pressure at the right and left slew relief
valves.
• If the measured value is within specifications, the
slew pressure is normal.
“2. Service data, Performance criteria”
If the pressure adjustment is possible, the adjustment
of the slew relief valve is faulty. If the pressure adjust-
ment is not possible, the slew relief valve is faulty.

5. Check the slew motor

Separate the slew motor (1) from the turntable (2), and
then try turning the turntable (2).
• Does not turn..... The slew bearing (3) is faulty.
• Turns ................. The slew motor (1) is faulty.
“4. Disassembly and assembly, Slew motor”

5-16
 5
TROUBLESHOOTING
SLEWING

Slew right or left is not possible

Faulty Repair or replace the pilot

1 Check the pilot valve
valve

Normal

Check the spool opera- Faulty Repair or replace the housing

2
tion block

Normal

Check the slew relief Faulty Repair or replace the slew re-
3
valve lief valve

Normal

Check the check valve of Faulty Repair or replace the brake

4
the slew brake valve valve

Normal

Repair or replace the slew

5 The slew motor is faulty
motor

1. Check the pilot valve

It is likely that only the pilot valve spool on the side
where slewing is not possible is faulty.
“5-16”

2. Check the spool operation

It is likely that the spool does not move in the direction
in which slewing is not possible.
“5-16”

3. Check the slew relief valve

Switch between the left and right slew relief valves. If
slewing becomes possible, the relief valve is faulty.

��������

5-17
 5
TROUBLESHOOTING
SLEWING

4. Check the check valve of the slew brake valve

If foreign matter is caught in one of the check valves
(1), or if the valve is sticking, right or left slewing does
not work.
• If foreign matter is caught in one of the check valves, �
the hydraulic oil returns from the check valve to the
tank.

��������

5. The slew motor is faulty

“4. Disassembly and assembly, Slew motor”

5-18
 5
TROUBLESHOOTING
SLEWING

Slewing is slow or lacks force

Is the time needed for Within specs

1 Normal
slewing within specs?

Slow

Faulty Repair or replace the pilot

2 Check the pilot valve
valve

Normal

Check the spool opera- Faulty Repair or replace the housing

3
tion block

Normal

Pressure too low Adjust the slew relief valve

4 Check the slew pressure Adjust to set pressure
pressure

Normal

Pressure does not rise Repair or replace the relief

valve

Check the check valve of Faulty Repair or replace the brake

5
the slew brake valve valve

Normal

Inspect the slew drive re- Faulty Repair or replace the slew
6
duction gears drive reduction gears

Slew bearing is faulty Replace

5-19
 5
TROUBLESHOOTING
SLEWING

1. Is the time needed for slewing within specifica-

tions?
“2. Service data, Performance criteria”

2. Check the pilot valve

“5-16”

3. Check the spool operation

“5-16”

4. Check the slew pressure

“5-16”

5. Check the check valve of the slew brake valve

“5-18”

6. Inspect the slew drive reduction gears

“4. Disassembly and assembly, Slew motor”

5-20
 5
TROUBLESHOOTING
SLEWING

The machine slews, but overruns a lot when slewing stops, or slewing cannot be stopped

Is the amount of overrun

Within specs
1 when slewing stops with- Normal
in specs?
Out-of-specs

Faulty Repair or replace the pilot

2 Check the pilot valve
valve

Normal

Check the spool opera- Faulty Repair or replace the housing

3
tion block

Normal

Check the check valve of Faulty Repair or replace the brake

4
the slew brake valve valve

Normal

Pressure too low Adjust the slew relief valve

5 Check the slew pressure Adjust to set pressure
pressure

Pressure does not rise Repair or replace the relief

valve

1. Is the amount of overrun when slewing stops within

specs?
“2. Service data, Performance criteria”

2. Check the pilot valve

Check if the spool of the pilot valve returns to the neu- �

tral position when the operation lever (slew) is released �

��
after operation. Disconnect the hose connecting the ��
��
pilot valve and control valve (slew block) from the con- ��

trol valve. Fit the pressure gauge to the hose just dis-
connected.
• Operate the lever (slew) and then release it to read
the pressure gauge. ���
• If the pressure is zero, the pilot valve is normal. �

��������

5-21
 5
TROUBLESHOOTING
SLEWING

3. Check the spool operation

Check if the spool of the control valve (slew block) re-
turns to the neutral position when the operation lever �
(slew) is released after operation. Disconnect the hose
connecting the control valve (slew block) and the slew �
motor from the control valve. Fit the pressure gauge to ��
the discharge port on the control valve.
��
• Operate the lever (slew) and then release it to read
the pressure gauge.
• If the pressure is zero, the spool is normal.

��������

4. Check the check valve of the slew brake valve

“5-18”

5. Check the slew pressure

“5-16”

5-22
 5
TROUBLESHOOTING
SLEWING

When stopped on a slope, the upperstructure cannot maintain its posture

Is the slew spontaneous Within specs

1 Normal
drop within specs?

Out-of-specs

Adjust the relief valve

Pressure too low
2 Check the slew pressure pressure of the slew brake Adjust to set pressure
valve
Normal

Pressure does not rise Repair or replace the slew re-

lief valve

Faulty Repair or replace the slew

3 Check the slew motor
motor

1. Is the slew spontaneous drop within specs?

“2. Service data, Performance criteria”

2. Check the slew pressure

“5-16”

3. Check the slew motor

“4. Disassembly and assembly, Slew motor”

5-23
 5
TROUBLESHOOTING
BOOM

BOOM
The boom cylinder does not move

Check the operation of

1 actuators other than of
the boom cylinder
Normal

Faulty Repair or replace the pilot

2 Check the pilot valve
valve

Normal

Check the spool opera- Faulty Repair or replace the housing

3
tion block

Normal

Test by replacing the port Problem solved The port relief valve is Repair or replace the port re-
4
relief valve faulty lief valve

No change

Faulty Repair or replace the boom

5 Check the boom cylinder.
cylinder

1.Check the operation of actuators other than of the Device to check

boom cylinder Lever to operate
Relief valve Pump
Determine if only the boom cylinder is faulty by check-
TB228,235: R2 TB228,235: P2
ing the operation of actuators for the devices listed in Right travel
the table on the right. If one of them is faulty, check the TB250: R1 TB250: P1
main relief valve and the hydraulic pump (main).
“5-5”

5-24
 5
TROUBLESHOOTING
BOOM

2. Check the pilot valve

Disconnect the hose connecting the pilot valve and the
control valve (boom block) from the control valve. Fit
the pressure gauge to the hose just disconnected.
• Operate the lever (boom) and measure the pres- ��

sure. ��
���
• If the pressure is between 0 and 3.4 MPa depending
on the lever angle, the pilot valve is normal.
���

��������

3. Check the spool operation ��

Disconnect the hose connecting the control valve
(boom block) and the boom cylinder from the cylinder. ��
Fit the pressure gauge to the discharge port on the
control valve.
• Operate the lever (boom) and measure the pres-
sure.
Supply pressure: 21.0 MPa

��������

4. Test by replacing the port relief valve

Replace the port relief valve in question with a normal
port relief valve. If the boom cylinder operates with the
replacement valve, the port relief valve used on the
boom side is faulty.
Make sure to return the port relief valve to its regular
position after the above inspection.

��������

5. Check the boom cylinder.

a. Disconnect the hose connecting the control valve
and the boom cylinder from the control valve side.
b. Connect the hose just disconnected to the arm or
bucket block.
c. Try to operate the boom cylinder. If the cylinder fails
to operate, the cylinder is faulty.
Before performing steps “a” through “c” above, fully
extend the bucket cylinder, completely retract the
arm cylinder and lower the bucket to the ground.

��������

5-25
 5
TROUBLESHOOTING
BOOM

Boom cylinder operation is slow or lacks force

Is the speed of the boom Within specs

1 Normal
cylinder within specs?

Out-of-specs

Faulty Repair or replace the pilot

2 Check the pilot valve
valve

Normal

Check the spool opera- Faulty Repair or replace the housing

3
tion block

Normal

Test by replacing the port Problem solved The port relief valve is Repair or replace the port re-
4
relief valve faulty lief valve.

No change

Faulty Repair or replace the boom

5 Check the boom cylinder
cylinder

1. Is the speed of the boom cylinder within specs?

“2. Service data, Performance criteria”

2. Check the pilot valve

“5-25”

3. Check the spool operation

“5-25”

4. Test by replacing the port relief valve

“5-25”

5-26
 5
TROUBLESHOOTING
BOOM

5. Check the boom cylinder

Check the boom cylinder for internal leak (1)
a. Completely retract the bucket cylinder and the arm
cylinder. Extend the arm cylinder rod a little, and
then lower the bucket end to the ground.

��������

b. Disconnect only the rod side hose (A) and drain oil
from the piping. Insert a plug (1) into the hose just
disconnected.

� �
��������

c. Retract the arm cylinder and lift the bucket off the
ground. If oil leaks from the cylinder piping that the
hose was disconnected from, and if the boom cylin-
der rod is retracted, the cylinder is leaking internally.
If there is no oil leak from the cylinder piping but the
boom cylinder rod is retracted, the control valve is
leaking internally.

��������

Check the boom cylinder for internal leak (2)

a. Set the machine in the posture shown in the figure.

��������

5-27
 5
TROUBLESHOOTING
BOOM

b. Disconnect the head side hose (A) and drain oil from
the piping. Insert a plug (2) into the hose just discon- � �
nected.

��������

c. Operate the bucket to raise the machine body. If

oil leaks from the cylinder piping the hose was dis-
connected from while the boom cylinder rod is ex-
tended, the cylinder is leaking internally.
If there is no oil leak from the cylinder piping but the
boom cylinder rod is extended, the control valve is
leaking internally.
If the cylinder is damaged internally, the system
must be flushed out to remove any debris.

��������

5-28
 5
TROUBLESHOOTING
BOOM

When the boom control lever is pulled slowly, the boom drops at first

Check the load check Faulty Repair or replace the housing

1
valve of the control valve block

Normal

Check for leakage inside Faulty Repair or replace the boom

2
the boom cylinder cylinder

1. Check the load check valve of the control valve

a. Disconnect the hose connecting the control valve
and the boom cylinder from the control valve.
b. Connect the hose just disconnected to the boom or
bucket block.
c. Try to operate the boom cylinder.
If operation is normal, the load check valve is faulty.
Before performing steps “a” through “c” above, set
the machine as follows.
• Fully extend the bucket cylinder, completely re-
tract the arm cylinder and lower the bucket to the
ground.
When the spool first starts to pull, the oil’s pressure ��������

and the flow rate are small, so if the load check valve
is faulty, it causes a load to act on the boom cyl-
inder, which causes the oil to flow backward for a
time. This is what causes the boom to drop at first.

2. Check for leak inside the boom cylinder

If the oil is leaking from the head side (A) to the rod
side (B) due to a faulty arm cylinder piston or tube, the
�
lift arm first drops because of the low oil pressure and
small flow rate when the spool begins to pull. The driv- �
ing force of the cylinder is also insufficient. In this case,
the spontaneous drop of the boom becomes large.
• Check the cylinder
“5-27 and 28”

��������

5-29
 5
TROUBLESHOOTING
BOOM

Spontaneous drop of the boom cylinder is too large

Is the spontaneous drop

Within specs
1 of the boom cylinder with- Normal
in specs?
Out-of-specs

Check for leak inside the Faulty Repair or replace the boom
2
boom cylinder cylinder

Normal

Test by replacing the port Problem solved The port relief valve is Repair or replace the port re-
3
relief valve faulty lief valve.

No change

Oil leak inside the control valve Replace the housing block.

1. Is the spontaneous drop of the boom cylinder with-

in specs?
“2. Service data, Performance criteria”

2. Check for leak inside the boom cylinder

“5-27 and 28”

3. Test by replacing the port relief valve

5-30
 5
TROUBLESHOOTING
ARM

ARM
Arm cylinder does not move

Check the operation of

1 actuators other than of
the arm cylinder
Normal

Faulty Repair or replace the pilot

2 Check the pilot valve
valve

Normal

Check the spool opera- Faulty Repair or replace the housing

3
tion block

Normal

Test by replacing the port Problem solved The port relief valve is Repair or replace the port re-
4
relief valve faulty lief valve.

No change

Faulty Repair or inspect the arm cyl-

5 Check the arm cylinder.
inder

1. Check the operation of actuators other than of the Device to check

arm cylinder Lever to operate
Relief valve Pump
Determine if only the arm cylinder is faulty by checking
TB228,235: R1 TB228,235: P1
the operation of actuators for the devices listed in the Left travel
table on the right. TB250: R2 TB250: P2
If it is faulty, check the main relief valve and the hydrau-
lic pump (main).
“5-5”

2. Check the pilot valve ���

Disconnect the hose connecting the pilot valve and the
control valve (arm block) from the control valve. Fit the ��

pressure gauge to the hose just disconnected.

��
• Operate the lever (arm) and measure the pressure. ��� ���
• If the pressure is between 0 and 3.4 MPa depending
on the lever angle, the pilot valve is normal.

���
�

��������

5-31
 5
TROUBLESHOOTING
ARM

3. Check the spool operation

Disconnect the arm hose connected to the pipe at the
boom foot, then install a pressure gauge in the discon-
nected hose.
• Operate the lever (arm) and measure the pressure.
• If the measured value is within the specifications, the
spool is normal.
Supply pressure: 21.0 MPa

��������

4. Test by replacing the port relief valve

Replace the port relief valve in question with a normal
port relief valve. If the arm cylinder operates with the re-
placement valve, the port relief valve used on the boom
side is faulty.
Make sure to return the port relief valve to its regular
position after the above inspection.

��������

������� ��������

5. Check the arm cylinder

Switch between the arm hose and the bucket hose
connected to the piping at the boom foot.
• Move the lever (bucket) and try to operate the arm
cylinder.
• If the cylinder fails to operate, it is faulty.
Before performing the steps above, fully extend the
bucket cylinder, completely retract the arm cylinder
and lower the bucket to the ground.

��������

5-32
 5
TROUBLESHOOTING
ARM

Arm cylinder operation is slow or lacks force

Is the speed of the arm Within spec

1 Normal
cylinder within spec?

Out-of-spec

Faulty Repair or replace the pilot

2 Check the pilot valve
valve.

Normal

Check the spool opera- Faulty Repair or replace the housing

3
tion block.

Normal

Test the port relief valve Problem solved Repair or replace the port re-
4 The port relief valve faulty
with a replacement valve lief valve.

No change

Check for leak inside the Faulty Repair or replace the arm cyl-
5
arm cylinder inder.

1. Is the speed of the arm cylinder within spec?

“2. Service data, Performance criteria”

2. Check the pilot valve.

“5-31”

3. Check the spool operation.

“5-32”

4. Test the port relief valve with a replacement valve.

“5-32”

5-33
 5
TROUBLESHOOTING
ARM

5. Check for leak inside the arm cylinder

a. Fully retract the bucket cylinder and the arm cylin-
der, and then lower the bucket to the ground.

��������

b. Disconnect the two hoses connected to the cylin-

der. Insert plugs (1) into the disconnected hoses and �
the cylinder piping.

��������

c. Raise the boom and lift the hoe attachment off the
ground. If the arm drops, the cylinder is faulty. If not,
there is a leak inside the control valve.

��������

5-34
 5
TROUBLESHOOTING
ARM

Spontaneous drop of the arm is too large

Is the spontaneous drop

Within specs
1 of the arm cylinder within Normal
specs?
Out-of-specs

Faulty Repair or replace the arm cyl-

2 Check the arm cylinder
inder

1. Is the spontaneous drop of the arm cylinder within

specs?
“2. Service data, Performance criteria”

2. Check the arm cylinder

“5-34”

5-35
 5
TROUBLESHOOTING
BUCKET

BUCKET
Bucket cylinder does not move or lacks force

Check the operation of

1 actuators other than of
the bucket cylinder
Normal

Faulty Repair or replace the pilot

2 Check the pilot valve
valve

Normal

Check the spool opera- Faulty Repair or replace the housing

3
tion block

Normal

Test by replacing the port Problem solved The port relief valve is Repair or replace the port re-
4
relief valve faulty lief valve

No change

Check the bucket cylin- Faulty Repair or replace the bucket

5
der. cylinder

1. Check the operation of actuators other than of the Device to check

bucket cylinder Lever to operate
Relief valve Pump
Determine if only the bucket cylinder is faulty by check-
TB228, 235: R2 TB228, 235: P2
ing the operation of actuators for the devices listed in Right travel
the table on the right. If one of them is faulty, check the TB250: R1 TB250: P1
main relief valve and the hydraulic pump (main).
“5-5”

2. Check the pilot valve

Disconnect the hose connecting the pilot valve and the
control valve (bucket block) from the control valve. Fit
the pressure gauge to the hose just disconnected.
��
• Operate the lever (bucket) and measure the pres- ��
���
sure.
• If the pressure is between 0 and 3.4 MPa depending
on the lever angle, the pilot valve is normal.

3. Check the spool operation

���
“5-32”

��������

5-36
 5
TROUBLESHOOTING
BUCKET

4. Test by replacing the port relief valve

Replace the port relief valve in question with a port re-
lief valve used for a normal boom. If the bucket cylinder
operates normally with the replacement valve, the port
relief valve used on the bucket side is faulty.

��������

5. Check the bucket cylinder

Switch between the arm hose and the bucket hose
connected to the piping at the boom foot.
• Move the lever (arm) to operate the bucket cylinder.
• If the cylinder fails to operate, it is faulty.
Before performing the steps above, fully extend the
bucket cylinder, completely retract the arm cylinder
and lower the bucket to the ground.

��������

5-37
 5
TROUBLESHOOTING
BUCKET

Spontaneous drop of the bucket is too large

Is the spontaneous drop

Within specs
1 of the bucket cylinder Normal
within specs?
Out-of-specs

Check the bucket cylin- Faulty Repair or replace the bucket

2
der cylinder

Normal

Oil is leaking inside the control

Replace the housing block
valve

1. Is the spontaneous drop of the bucket cylinder

within specs?
“2. Service data, Performance criteria”

2. Check the bucket cylinder

a. Fully extend the bucket cylinder, completely re-
tract the arm cylinder, and lower the bucket to the
ground.
b. Disconnect the two hoses connected to the cylin-
der. Insert plugs (1) into the disconnected hoses and �
the piping.

��������

c. Raise the boom and lift the hoe attachment off the
ground. If the bucket drops, the cylinder is faulty. If
not, there is a leak inside the control valve.

5-38
 5
TROUBLESHOOTING
BOOM SWING

BOOM SWING
Swing cylinder does not move

Check the operation of

1 actuators other than of
the swing cylinder
Normal

Check the spool opera- Faulty Repair or replace the housing

2
tion block

Normal

Faulty
3 Check the linkage Adjust, repair or replace

Normal

Check the anti-cavitation Faulty Repair or replace the anti-cav-

4
valve itation valve

Normal

Faulty Repair or replace the swing

5 Check the swing cylinder
cylinder

1. Check the operation of actuators other than of the Device to check

swing cylinder Lever to operate
Relief valve Pump
Determine if only the boom swing cylinder is faulty by
TB228, 235: R1 TB228, 235: P1
checking the operation of actuators for the devices Left travel
listed in the table on the right. If one of them is faulty, TB250: R2 TB250: P2
check the main relief valve and the hydraulic pump
(main).
“5-5”

2. Check the spool operation

• Spool stroke: 8 mm
• If the spool is sticking, try to take it out.
If it can’t be taken out or is scratched, replace the
housing block.
Note that the faulty spool operation could be caused
by the loosened bolt used for the return spring.

��������

5-39
 5
TROUBLESHOOTING
BOOM SWING

3. Check the linkage

To check the linkage, remove the R pin (2) and pin (3)
used to connect the spool and the yoke (1) , and then
inspect the yoke (1) movement.

� ���������

4. Check the anti-cavitation valve

If only the right swing is inoperable, it is likely that for-
eign matter is caught in the anti-cavitation valve or the
valve is sticking.

5. Check the swing cylinder

Disconnect the hose connecting the swing cylinder
and the control valve from the control valve and mea-
sure the supply pressure in the control valve. If the sup-
ply pressure is normal, the swing cylinder is faulty.
• If the measured value is as below, the supply pres-
sure is normal.
Supply pressure: 21.0 MPa

5-40
 5
TROUBLESHOOTING
DOZER BLADE

DOZER BLADE
Dozer blade cylinder does not move or lacks force.

Check the operation of

1 actuators other than of
the dozer blade cylinder
Normal

Check the spool opera- Faulty Repair or replace the housing

2
tion block

Normal

Faulty
3 Check the linkage Adjust, repair or replace

Normal

Check the supply pres- Faulty Repair or replace the housing

4
sure of the control valve block

Normal

Faulty Repair or replace the swivel

5 Check the swivel joint
joint

Normal

Repair or replace the dozer

Dozer blade cylinder is faulty
blade cylinder

1. Check the operation of actuators other than of the Device to check

dozer blade cylinder Lever to operate
Relief valve Pump
Determine if only the dozer blade cylinder is faulty by
Slew R3 P3
checking the operation of actuators for the devices
listed in the table on the right. If one of them is faulty,
check the main relief valve and the hydraulic pump
(main).
“5-5”

2. Check the spool operation

“5-39”

3. Check the linkage

“5-39”

5-41
 5
TROUBLESHOOTING
DOZER BLADE

4. Check the supply pressure of the control valve

Disconnect one of the hoses connected to the control
valve housing block (blade). Fit the pressure gauge to �
the hose just disconnected. Operate the lever (blade) ��
�
and check the supply pressure of the valve.
• If the value indicated is not as below, the housing
block is faulty.
Supply pressure: 19.6 MPa ��

��������

When only “Dozer Blade Lower” is impossible

• Replace the port relief valve in question with a port
relief valve used for a normal arm. If the dozer blade
cylinder operates normally with the replacement
valve, the port relief valve used on the dozer blade
side is faulty.
��������

����������������
��������

5. Check the swivel joint

Disconnect the hose connecting the swivel joint and
the blade cylinder from the blade cylinder. Fit a pres-
sure gauge to the hose just disconnected and operate
the lever (blade).
• If the value indicated is not as below, the swivel joint
is faulty.
Supply pressure: 19.6 MPa

5-42
 5
TROUBLESHOOTING
DOZER BLADE

The spontaneous drop of the dozer blade is too large, or the dozer blade cannot support the machine

Is the spontaneous drop

Within specs
1 of the dozer blade within Normal
specs?
Out-of-specs

Check for leakage inside Faulty Repair or replace the housing

2
the dozer blade cylinder block

Normal

Inspect the swivel joint Faulty Repair or replace the swivel

3
and the control valve joint or control valve

1. Is the spontaneous drop of the dozer blade within

specs?
“2. Service data, Performance criteria”

2. Check for leakage inside the dozer blade cylinder

a. Using the hoe attachments, raise the machine, then
lower the blade fully.

��������

b. Disconnect the hose from the rod side of the dozer

blade cylinder and drain oil from the piping.
Install the plug (1) on the hose just disconnected.

��������

5-43
 5
TROUBLESHOOTING
DOZER BLADE

c. Raise the dozer boom and apply a load on the

blade.
• If the machine drops while oil drains from the
cylinder’s piping, the cylinder is faulty.
If the machine drops even though no oil drains
out, the control valve or the swivel joint is faulty.
If the machine cannot be supported by the blade,
try replacing the port relief valve with a normal
one. If the blade can support the machine af-
ter this replacement, then the port relief valve is
faulty.

��������

3. Inspect the swivel joint and the control valve

Disconnect the hose connecting the swivel joint and
control valve from the control valve. Insert a plug into �
the hose just disconnected. ��
�
Apply a load to the blade by following the steps 2 (a)
through (c) above.
If the machine drops, the swivel joint is faulty.
If the machine does not drop, there is a leak inside the ��
control valve.

��������

5-44
 5
TROUBLESHOOTING
AUXILIARY HYDRAULICS

AUXILIARY HYDRAULICS
Proportional control is not possible

Check the operation of

1 actuators other than of
the auxiliary piping
Normal

Check the proportional Faulty Repair or replace the propor-

2
controller tional controller

Normal

Check the proportional Faulty Repair or replace the propor-

3
control solenoid valve tional control solenoid valve

1. Check the operation of actuators other than of the

auxiliary piping
Determine if only the auxiliary piping is faulty by check- Lever to operate Device to check
ing the operation of actuators for the devices listed in Bucket Relief valve R3 Pump P3
the table on the right. If one of them is faulty, check the
main relief valve and the hydraulic pump (P3).
“5-8”

2. Check the proportional controller

“4. Disassembly and assembly, Proportional con-
trol”

3. Check the proportional control solenoid valve

a. Disconnect the hose connecting the solenoid valve ���
and the control valve (auxiliary section) from the
control valve.
b. Fit the pressure gauge to the hose just disconnect-
ed.
c. Operate the proportional control lever on the left pi-
���
lot valve. If the pressure is between 0 and 3.4 MPa
depending on the lever angle, the proportional con-
trol solenoid valve is normal.
�
�

��������

5-45
 5
TROUBLESHOOTING
PISTON PUMP

PISTON PUMP
Symptoms Major causes Remedies
Noise is too loud, unusual • Suction hose is crushed or suction filter • Remove the dirt and correct the crushing.
sound is heard is clogged
• Joint in the suction side is loose and • Retighten each joint.
sucking air
• Cavitation is being produced due to too • Replace with hydraulic oil of proper viscosity.
high viscosity of the hydraulic oil
• Pump and engine are not center • Center them again.
aligned
• Frothing of hydraulic oil • Investigate the cause of frothing and correct it.
• Engine RPM is too high • Run at the rated RPM.
• Mechanical damage to the parts (e.g., • Replace the damaged part(s) or the pump.
bearing)
Discharge is insufficient • Engine RPM is too low • Run at the rated RPM.
• Oil temperature is too high • Stop running, and check the temperature again
after the oil cools down.
• Viscosity of hydraulic oil is too high • Replace with hydraulic oil of proper viscosity.
• Pump volume efficiency becomes low • Replace the pump.
• Hydraulic oil tank level is too low • Add oil to the specified level.
• Clogging in the suction piping or the • Clean the piping.
suction filter
• Leak volume of hydraulic devices other • Repair or replace the leaking hydraulic device.
than the pump is increased
Pressure is not increased • Set pressure for the relief valve drops • Set the relief valve pressure again.
• Leak volume of hydraulic devices other • Repair or replace the leaking hydraulic device.
than the pump is increased
• Pump volume efficiency becomes low • Replace the pump.
Abnormal heat is gener- • Leak volume from the pump is in- • Replace the pump.
ated creased
• Mechanical damage to the parts (e.g., • Replace the damaged part(s) or the pump.
bearing)
• Seizing on the sliding part • Replace the damaged part(s) or the pump.
Oil leak • Seals are damaged • Replace the seal(s).
• Sliding part between the shaft and the • Replace the shaft or the pump.
oil seal is worn out
• Plugs and bolts are loosened • Retighten the plugs and bolts, or replace the
seals.

5-46
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TROUBLESHOOTING
GEAR PUMP

GEAR PUMP
“4. Disassembly and assembly, Gear pump”

Symptoms Major causes Remedies

No discharging operation • Direction of rotation is incorrect • Rotate in the rated direction.
• Hydraulic oil tank level is too low • Add oil to the specified level.
• Clogging in the suction piping or the • Clean the piping.
suction filter
• Viscosity of hydraulic oil is too high • Replace with hydraulic oil of proper viscosity.
• RPM is too low • Run at the rated RPM.
Noise is too loud, unusual • Cavitation is being produced due to the • Remove the dirt and correct the crushing.
sound is heard crushed hose or clogged filter of the
suction side
• Joint in the suction side is loose and • Retighten each joint.
sucking air
• Cavitation is being produced due to too • Replace with hydraulic oil of proper viscosity.
high viscosity of the hydraulic oil
• Pump and engine are not center • Center them again.
aligned
• Frothing of hydraulic oil • Investigate the cause of frothing and correct it.
Oil leak from the oil seal • Oil seal is deformed, worn out or dam- • Replace the oil seal.
aged
Oil leak from the mat- • Body seal is damaged, or the sliding • Replace with a new one.
ing surface between the part is worn out
housing and the flange or
housing and the cover
Discharge is insufficient • Bushing seal is damaged • Replace the bushing seal.
• Cavitation is being produced • Clean the suction filter and the suction piping.
• Aeration is being produced • Check if piping is properly screwed in.
• The viscosity of hydraulic oil is too low • Replace with hydraulic oil of proper viscosity.

5-47
 5
TROUBLESHOOTING
CONTROL VALVE

CONTROL VALVE
“4. Disassembly and assembly, Control valve”
The problems are listed individually in the table below, but in reality, many problems have multiple causes. Therefore, try to
check and eliminate each possible cause one at a time.

Symptoms Major causes Remedies

Oil leak from the spool • Flaw is on the sealing part or the seal lip is • Replace with a new one.
seal worn out due to prolonged use
• Flaw (e.g., dents or scratches) on the sliding • Repair or replace the spool.
part of the seal is caused by an external fac-
tor
• The lid that is pushing the sealing parts in • Correct the lid, and determine the partial
place is installed improperly (lid is distorted) wear degree of the seal.
• Old paint remains on the seal sliding part of • Remove it by using thinner or mechanical
the spool force.
When removing, take care not to damage the
spool surface or the seal lip.
• Tank pressure becomes too high for the per- • Remove the cause of the flow resistance.
formance of the sealing material
Sliding part of the • Foreign matter is caught in the sliding part of • Overhaul and repair or replace.
spool is not smooth the spool
• Oil film between the spool and the body be- • Try to decrease the oil temperature. If the re-
comes too thin due to the increased oil tem- lief valve is started often, find the cause and
perature correct it.
• Lubrication is disabled due to deteriorated • Oil should be replaced. The circuit also
oil should be overhauled in some cases.
• Spool is worn out because of prolonged use • Replace the spool and the valve block as-
or of the unbalanced force applied sembly.
• Spool is bent by the external force • Check for the straightness of the spool, and
repair or replace.
• Whole Valve is distorted due to the distortion • Check the distortion, independent of the
of the installation surface installation surface (loosening the bolts will
help).
• Valve is operated with the pressure or the • For pressure, measure it with a pressure
flow rate of out-of-spec gauge. For flow rate, determine it by finding
out the movement speed and capacity of the
actuator.
• Fixing bolts are over-tightened • Check if the fixing bolts are tightened with the
specified torque. If not, tighten them again
with the specified torque.
• Oil stays in the lid (spring or detent) opposite • Oil may come out from the lid, if it is leaking
to the spool operation in the seal of the spool. If that is the case,
replace the seal.
When the actuator is • Foreign matter is caught in the seat on the • Disassemble the valve and overhaul or re-
being raised, it drops load check valve, or the seat is damaged by place the faulty part(s).
once large foreign matter

5-48
 5
TROUBLESHOOTING
CONTROL VALVE

Symptoms Major causes Remedies

Spool’s neutral posi- • There are cases of a large oil leak inside the • Check if the cylinder drops spontaneously
tion cannot be main- cylinder when it is held. If the cylinder is faulty, disas-
tained (cylinder drops) semble and repair it.
• Since the clearance between the spool and • Replace the spool and the valve block as-
the body is too large, oil is leaking from the sembly.
clearance
• Spool is not completely back in the neutral • Manual: Check if the link mechanism is inter-
position fering with others.
Hydraulic operation: Check the pilot pres-
sure.
• Foreign matter is caught in the seat of the • Disassemble, overhaul or replace.
port relief valve or of the anti-cavitation valve,
and thus the oil is bypassing the section. Or,
the seat is damaged
Load cannot be • Foreign matter is caught in the seat of the • Disassemble, overhaul or replace.
moved (pressure can- port relief valve, and thus the oil is bypassing
not be increased) the section. Or, the seat is damaged
• Adjuster screw on the relief valve is loose • Screw in the adjuster screw. If loose, set the
adjustment again and fasten with a lock nut.
• Foreign matter is caught in the seat of the • Disassemble, overhaul or replace.
port relief valve or of the anti-cavitation valve,
and thus the oil is bypassing the section. Or
the seat is damaged
• Spool stroke is out-of-spec • Manual: Check if the link mechanism is inter-
fering with others. Check if the pin or pin hole
on the linking section is worn out.
• Oil supply from the pump is insufficient, be- • Hydraulic operation: Check the pilot pres-
cause the pump is damaged sure.
Check for any abnormality in the pump.
If the pump is faulty, replace it and find the
cause of the abnormality (e.g., faulty air suck-
ing or oil degradation).
Load cannot be • Overloading • Compare with a one with standard load.
moved (pressure is • Mechanical resistance of related parts/de- • Check and add oil, modify or repair the parts/
being increased) vices (unrelated to the hydraulic pressure of devices.
the hydraulic oil) is large
• Large resistance is generated, because the • Repair if the location of clogging or bent is
circuit is clogged with large foreign matter or known.
the piping is bent
• Spool stroke is out-of-spec • Check if the link mechanism is interfering
with others and if the pin or pin hole on the
linking section is worn out.
When the arm float • Foreign matter is caught in the pilot valve or • Disassemble and clean. If the damage is
is operated, the float the valve is stuck large, replace the pilot valve.
function fails. • The pilot spool is stuck • Control of the hydraulic oil contamination
• Overloaded • Remove the overloading
• Floating is impossible due to low Pp port • Measure the Pp pressure.
pressure
• Solenoid wire is broken • Replace the solenoid.

5-49
 5
TROUBLESHOOTING
PILOT VALVE

PILOT VALVE
“4. Disassembly and assembly, Pilot valve”

Symptoms Major causes Remedies

The secondary pressure • The primary pressure is insufficient • Keep the sufficient primary pressure.
is too low • The spring is broken or worn out • Replace.
• The clearance between the spool and the • Replace the spool and the casing assembly.
casing is too large
• Too much play in the handle • Disassemble and assemble or replace.
The secondary pressure • The sliding part is not smooth • Correct or replace.
is unstable • The tank line pressure fluctuates • Remove the faulty part(s) in the tank line.
• Air is present in the piping • Bleed air by operating the valve several
times.
The secondary pressure • Pressure in the tank line is high • Remove the faulty part in the tank line.
is high • The sliding part is not smooth • Correct or replace.

5-50
 5
TROUBLESHOOTING
PROPORTIONAL CONTROL SOLENOID VALVE

PROPORTIONAL CONTROL SOLENOID VALVE

“4. Disassembly and assembly, Proportional control solenoid valve”

Symptoms Major causes Remedies

Solenoid valve does not operate • Wiring short-circuit or wire break • Replace.
• Coil assembly short-circuit or wire break • Replace.
• Catching of foreign matter by the spool • Overhaul and repair or replace.
• Damage on the outer circumference of • Overhaul and repair or replace.
the spool
• Defective proportional controller • Repair or replace.
• Primary pressure is insufficient • Keep the primary pressure.
Oil leakage from solenoid valve • Damaged O-ring • Replace.
• Damaged seal nut • Replace.

5-51
 5
TROUBLESHOOTING
CYLINDERS

CYLINDERS
“4. Disassembly and assembly, Cylinder”

Symptoms Major causes Remedies

Oil leak from the piston rod sliding part • Foreign matter is caught in the inter- • Remove the foreign matter.
(oil stays on the surface in a ring shape; nal part of the rod packing or dust
this “oil ring” becomes larger and starts seal
dripping) • Flaw or abnormal condition of the in- • Replace the faulty part(s).
ternal lip surface of the rod packing
or dust seal
• Flaw on the sliding surface of the • Deburr/smooth the sliding surface
piston rod with an oilstone (1.6 S or less).
• If the leak still persists after deburr-
ing/smoothing, replace the seals
(e.g., rod packing).
• If the leak still persists after replacing
the seals, replace the piston rod.
• Peeling on a hard chromium plated • Redo the hard chromium plating.
surface
Oil leak from the rod cover perimeter • O-ring is damaged • Replace the faulty part(s).
• Backup ring is damaged • Replace the faulty part(s).
Oil leak from the welded part • Tube’s welded part is damaged • Replace the faulty part(s).
Spontaneous drop of cylinder (“spon- • Foreign matter is caught in the slid- • Remove the foreign matter.
taneous drop” refers to a piston condi- ing surface of the wear ring
tion that its maximum movement in 10 • Flaw or abnormal condition on the • Replace the faulty part(s).
minutes is 0.5 mm or more when the sliding part of the wear ring
static load is exerted on the rod. The • Flaw on the sliding part of the piston • Replace the faulty part(s).
static load is determined by multiplying packing
the maximum operating pressure by • O-ring is damaged • Replace the faulty part(s).
the cylinder area)

5-52
 5
TROUBLESHOOTING
TRAVEL MOTOR

TRAVEL MOTOR
“4. Disassembly and assembly, Travel motor”

Hydraulic motor
Symptoms Major causes Remedies
Motor fails to start • All the devices other than the motor and the • Check whether the specified pressure
reduction gears are not working correctly is generated in the inlet port, and then
check and repair each device.
• Pressure oil is not flowing properly due to ab- • Replace the abnormally worn out part(s).
normal wear of the motor’s sliding part
• Motor is faulty, as its main components are • Replace the damaged part(s).
damaged
Rated speed cannot be • Specified volume of flow is not supplied to • Check whether the specified pressure
obtained the motor due to the faulty oil pump is generated in the inlet port, and then
check and repair each device.
• Motor volume efficiency becomes low • Check if there is abnormal wear on the
sliding part; if so, repair or replace it.
Rotational fluctuations are • High-pressure oil is leaking from the drain • Replace the abnormally worn part, if any.
large port, because the motor’s sliding part is worn
out
• Bearing is worn out • Replace the abnormally worn part, if any.
Oil leak • Oil leak due to breakage of oil seal and O- • Replace the oil seal and O-ring.
ring
• Oil seal is broken by the internal pressure • Repair the motor and replace the oil
generated in the motor case due to the ab- seal.
normal wear of the sliding part of the motor
• Pressure increase in the drain piping caused • Clean the clogging in the drain piping and
by the clogging of foreign matter resulted in replace the oil seal.
breakage of oil seal

2nd speed control

Symptoms Major causes Remedies
Straight-ahead traveling level Spool cannot be switched
is low, switching to 2nd speed • Foreign matter is caught • Remove foreign matter and correct or re-
travel is disabled place the faulty part(s).
• Spring is missing • Install the spring.
• Spring is damaged • Replace the spring.
• Oil leak due to the abnormal wear of • Replace the 2nd speed control piston.
the 2nd speed control piston
• 2nd speed control piston is missing • Install the 2nd speed control piston.
• Ball is abnormally worn out • Replace the ball.

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TROUBLESHOOTING
TRAVEL MOTOR

Parking brake
Symptoms Major causes Remedies
Braking force is insufficient • The total thickness of three friction discs • Replace the discs.
or not evenly applied and four center discs is 13.5 mm or less
• Disc surface is faulty • Repair or replace.
• Spring is damaged • Replace the spring.
• Bolt for manual releasing is being fitted • Remove the bolt for manual release, and fit
the plug.
Abnormal heat generation Release of braking is faulty
due to brake drag • Oil leak due to O-ring breakage • Replace the O-ring.
• Orifice is clogged • Clean the orifice.
• Pilot pressure for the releasing is not • Check whether the specified pressure is gen-
working erated in the pilot port, and then check and
repair each device.

5-54
 5
TROUBLESHOOTING
SLEW MOTOR

SLEW MOTOR
If you notice that the noise or heat becomes unusually high, it is likely that there is a fault in the machine. If it occurs, stop
the machine immediately and try to locate the faulty section.
The table below shows the cause of the general problem and action to be taken when such problem occurs in the hydraulic
circuits.
Hydraulic motor, brake valve
Symptoms How/Where? Major causes Remedies
• No pressure at the motor’s inlet • Set pressure of relief valve is too • Set correctly
Motor fails to start
port low
• Pump faulty • Repair or replace
• Control valve faulty • Repair or replace
• There is pressure at the motor’s • Load is too heavy • Reduce the load
inlet port • Hydraulic motor is faulty • Repair or replace
• Reduction gears are faulty • Replace the reduc-
tion gears
Motor does not • Pump discharge is insufficient • Too much drain from the pump • Repair or replace
speed up the pump
• Functional problem of the motor • Drop in the motor’s volumetric ef- • Replace the motor
ficiency
Oil is leaking • Leaking from an oil seal • Lip is faulty • Replace the oil seal
• Leaking from the mating surface • Bolts are loose • Retighten the bolts
• O-ring is faulty • Replace
• Mating surface is scratched • Repair the surface
with a grindstone or
sand paper
Motor produces • Noise in the piping • Piping support is faulty • Clamp the piping
abnormal noise
Temperature in- • Lubricating oil • Oil level is low • Add oil
crease at the re- • Hydraulic oil is entered • Replace the reduc-
duction gears tion gears
• Gear unit • Bearings are damaged • Replace the reduc-
tion gears
• Gear surfaces are damaged • Replace the reduc-
tion gears

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 5
TROUBLESHOOTING
SLEW MOTOR

Parking brake
Symptoms Major causes Remedies
Cannot release the • Release pressure PB and valve • Set the release pressure PB and valve switching signal
brake. Brake force is switching signal pressure SH are pressure SH as specified.
weak. Brake drags, not generated. Supply pressure is
produces noise, heat low.
• Valve does not operate due to high • Check the drain circuit for clogging and repair. If drain
drain pressure from the motor is too large, check and repair the mo-
tor.
Timing valve does not change over
• Sliding parts are worn or dam- • Repair or replace the sliding parts
aged
• Foreign matter is caught • Remove the foreign matter and repair or replace the
sliding parts
• A spring is broken • Replace
Brake piston does not operate
• O-rings are abnormally worn • Replace
• Sliding parts are worn or dam- • Repair or replace the sliding parts
aged
• Foreign matter is caught • Remove the foreign matter and repair or replace the
sliding parts
• Wear-resistant material is worn • Replace
• A spring is broken • Replace

5-56
 5
TROUBLESHOOTING
AIR CONDITIONER

AIR CONDITIONER
“4. Disassembly and assembly, Air conditioner”

A The outlets temperature cannot be changed

Note:
1. After completion of repair work, make sure to reinstall the connectors removed for inspection.
2. Check if there is warm water at the IN side of the water valve.
3. By referring to the wiring diagram, check for continuity of the lines between the air conditioner harness connectors
beforehand.

The attenuator is Replace

faulty
Check the temperature controlling operation YES

Turn on the starter switch and then the air conditioner Is the voltage be- Replace the amplifier
switch (10R20R3). Turn the attenuator and check if the tween the green/
voltage changes from 0 to 5 V between the following black and yellow/
wires of Connector (2). NO white wires 5 V? NO
• The green/black and green/white
• The green/black and yellow/black
(See the description about the temperature adjusting
switch below.)

YES YES

Does the water valve rod in the control box move with Water valve is Remove Connectors (1) and (2).
the output of the temperature control dial? YES faulty Check for continuity of the wires (yel-
low/white, yellow/black, green/white,
green/black of Connector (1)) and Con-
nector (2)
NO NO
Repair the wire break/disconnection

Check if something is interfering with the link of the wa- YES Remove the interfering thing or repair
ter valve assembly or the operation of the water valve or replace faulty parts
motor actuator. Is there anything interfering?

NO

Turn off the starter switch and remove Connectors (1), Repair the wire break/disconnection
(11), (12). Check for continuity in the wires (light green, NO
blue, yellow, green/yellow, red/white, white) of Connec-
tors (1) and (11). Are they electrically continuous?

YES

Check for mutual short-circuiting in the six wires con- YES After repairing, perform a test opera-
necting the motor actuator and the lamp. Is there a tion. If the problem still exists, replace
short circuit? the control amplifier (it could be dam-
aged by short-circuiting)
NO

Replace with a water valve motor actuator for testing, NO Control amplifier Replace the control amplifier
and connect the connectors removed. Perform a test is faulty
operation. Is the operation normal?

YES
Water valve motor Replace the water valve motor actua-
actuator is faulty tor

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 5
TROUBLESHOOTING
AIR CONDITIONER

B. Compressor clutch does not engage

Note:
1. After completion of repair work, make sure to reinstall the connectors removed for inspection.
2. Checking the items marked with * is not possible unless you have added refrigerant to the system and the ambient
temperature is at least 2°C.

Turn off the starter switch and remove Connector (13)

from the compressor

Turn on the starter switch, set the fan switch to 1, 2 or 3,

and set the temperature control dial to COOL

※
Measure the voltage between the female bullet con- YES Compressor Repair or replace the compressor
nector and ground connected to the compressor. Is it clutch is faulty
10-15V?

NO

※
Turn off the starter switch and remove Connector (12). NO Pressure switch is Replace the receiver-dryer
Check the pressure switch of the receiver-dryer for con- faulty
tinuity. Is there continuity?

YES

Is the compressor normal? NO Relay or relay cir- Replace the relay

cuit is faulty

YES

Is the voltage “0V” between the blue/red and ground of NO Blower switch is Replace the blower switch
Connector (4)? faulty

YES

Is the evaporator sensor normal? NO Evaporator sensor Repair the evaporator sensor cord or
(see the description for checking the evaporator sen- cord or evaporator replace the evaporator sensor
sor) sensor is faulty

YES

Control amplifier Replace the control amplifier

is faulty

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 5
TROUBLESHOOTING
AIR CONDITIONER

C. Blower motor does not rotate

Notes:
1. If the blower motor is apparently out of order, check the blower motor before checking other items listed below.
2. After completion of repair work, make sure to reinstall the connectors removed for inspection.

Is the fan switch normal? NO The fan switch is faulty Replace the fan switch

YES
Does the blower motor ro- When the starter switch Turn off the starter The blower Remove the
tate at 1, 2 or 3? is turned on, is 10-15V switch and remove the motor is foreign matter
NO applied in the white/ YES blower motor. YES locked by a
green to black, and the Any foreign matter in foreign matter
black/pink to black of the blower motor?
Connector (12)?
YES NO NO
Check if power is sup- Is there continuity in the NO Blower motor Replace the
plied to the machine blower motor? is faulty blow motor
YES
Does the blower motor ro- Remove Connector
tate at 3? NO (12). Check the blue/
black of Connector (7)
for continuity
YES
Any short circuits in the fan NO
switch-resistor?
NO
Repair the short circuit(s)

Turn off the starter switch

and remove Connector
(12).

Is the resistor normal? NO Resistor is faulty

YES
Fan switch is faulty Replace the resistor

Replace the fan switch

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TROUBLESHOOTING
AIR CONDITIONER

D. The air flow cannot be changed

Notes:
1. Before inspection, turn off the starter switch and remove the fan switch connector.
2. After completion of repair work, make sure to reinstall the connectors removed for inspection.

Cannot be changed be- Cannot be changed be- Cannot be changed be- Cannot be changed between
tween 1 and 2. tween 1 and 3. tween 2 and 3. 1, 2 and 3.

Check for short circuits in YES Check for short circuits in YES Check for short circuits in YES Check for short circuits in the
the blue/white and blue/ the blue/black and blue/ the blue/black and blue/ blue/white, blue/yellow and
yellow. Short-circuited? white. Short-circuited? yellow. Short-circuited? blue/black. Short-circuited?
NO NO NO NO YES

Air flow changeover

switch is faulty

Replace the air flow Repair the short circuit(s)

changeover switch

Resistor is faulty

Replace the resistor

5-60
 ENGINE 6

Machine model Mounted engine

TB250 4TNV88